Manufacturing Processes II

ISE 304N

Bulk-Forming Processes
Introduction

Middle Ages

Machining
• Turning
• Drilling
• Milling
• Grinding
Chapters 21, 22, 23, 24
Classification of Deformation Processes
Bulk deformation processes are those Sheet-forming operations involve the
processes where the thickness or cross deformation of materials whose thickness
sections are reduced and cross section remain relatively constant

Bulk deformation processes can be classified as primary or secondary processes

• Primary processes reduce a cast material into slabs plates, and billets
• Secondary processes reduce shapes into finished or semi-finished products
Bulk Deformation Processes
Rolling Wire, rode and tube drawing Extrusion

Piercing

Forging Cold forming, cold forging, Other squeezing processes

impact extrusion
Rolling
• Rolling operations reduce the
thickness or change the cross section
of a material through compressive
forces

• Often the first process that is used to

convert material into a finished
wrought product

• Thick stock can be rolled into blooms,

billets, or slabs
Rolling
• Metal is passed between two rolls that rotate in
opposite directions

• Friction acts to propel the material forward

• Metal is squeezed and elongates to compensate for

the decrease in cross-sectional area

Hot Rolling and Cold Rolling

• In hot rolling, temperature control is required for successful forming
o Temperature of the material should be uniform
o Rolling is terminated when the temperature falls to about 50 to 100 degrees above the recrystallization
temperature
o Ensures the production of a uniform grain size
• Cold rolling products sheet, strip, bar and rod products with smooth surfaces and accurate dimensions
Rolling
• Smaller diameter rolls produce less length
of contact for a given reduction and
require less force to produce a given
change in shape
• Smaller cross section provides a reduced
stiffness
o Rolls may be prone to flex elastically
because they are only supported on
the ends
Rolling
Continuous (Tandem) Rolling Mills
• Billets, blooms, and slabs are heated and fed
through an integrated series of non-reversing
rolling mills
• Synchronization of rollers may pose issues

Ring Rolling
• One roll is placed through the hole of a thick-walled ring
and a second roll presses on the outside
• Produces seamless rings
• Circumferential grain orientation and is used in rockets,
turbines, airplanes, pressure vessels, and pipelines
Rolling

Characteristics, Quality, and Precision of Rolled Products

• Hot-rolled products have little directionality in their properties
• Hot-rolled products are therefore uniform and have dependable quality
o Surfaces may be rough or may have a surface oxide known as mill
scale
• Dimensional tolerances vary with the kind of metal and the size of the
product
• Cold-rolled products exhibit superior surface finish and dimensional
precision
Rolling

Flatness Control and Rolling Defects

• Rollers must be evenly spaced throughout a) Loading on a rolling mill roll. The top roll is
for perfectly flat pieces to be produced pressed upward in the center while being
supported on the ends
b) The elastic response to the three-point
bending
• Sometimes this variation in roller “flatness”
may be desired
Rolling
Thermomechanical Processing and Controlled Rolling

• Heat may be used to reduce forces and promote

plasticity, but heat treatments are typically
subsequent operations

• Thermomechanical processing combines the

deformation and thermal processing into a single
shape with the desired properties

• Requires computer-controlled facilities

• Substantial energy savings

Forging
• Processes that induce plastic deformation
through localized compressive forces
applied through dies

• Oldest known metalworking process

• Parts can range in size

• Methods
o Drawing
o Upset
o Squeezed in closed impression dies
Forging
Open-Die Hammer Forging

• Same type of forging done by a blacksmith but mechanical

equipment performs the operation

• An impact is delivered by some type of mechanical hammer

• Simplest industrial hammer is a gravity drop machine

• Computer controlled-hammers can provide varying blows

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Forging

Impression-Die Hammer Forging • Excess metal may squeeze out of the die
• This metal is called flash
• The dies are shaped to control the flow of metal • Flashless forging can be performed if the metal is deformed
in a cavity that provides total confinement
• Upper piece attaches to the hammer and the lower piece • Many forged products are produced with a series of cavities
to the anvil o First impression is called edging, fullering, or bending
o Intermediate impressions are for blocking the metal to
• Metal flows and completely fills the die approximately its final shape
o Final shape is given in its final forging operation
Forging
Alternatives to Hammer and Anvil Arrangement

• Two hammers may form a work-piece

• Impactors operate with less noise and less vibration

Forging
Press Forging

• Press forging is used for large or thick

products
• Slow squeezing action penetrates completely
through the metal
o Produces a more uniform deformation
and flow
o Longer time of contact between the die
and work-piece
• Dies may be heated (isothermal forging)
• Presses are either mechanical or hydraulic

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Forging
Design of Impression-Die Forgings and
Associated Tooling

• Forging dies are typically made of high-alloy or tool steel

• Rules for better and more economical parts:
o Dies should part along a single, flat plane or follow
the contour of the part
o Parting surface should be a plane through the Impression-Die Forgings
center of the forging
o Adequate draft Important design details
o Generous fillets and radii o Number of intermediate steps
o Ribs should be low and wide o Shape of each step
o Various cross sections should be balanced o Amount of excess metal to fill the die
o Full advantage should be taken of fiber flow lines o Dimensions of flash at each step
o Dimensional tolerances should not be closer than o Good dimensional accuracy
necessary
Forging
Upset Forging

• Increases the diameter of a material by compressing its length

• Both cold and hot upsetting
• Three rules of upset forging
1. The length of the unsupported material that can be
gathered or upset in one blow without injurious
buckling should be limited to three times the diameter
of the bar.
2. Lengths of stock greater than three times the diameter
may be upset successfully provided that the diameter of
the upset is not more than 1 times the diameter of the
bar.
3. In an upset requiring stock length greater than three
times the diameter of the bar, and where the diameter
of the cavity is not more than 1 times the diameter of
the bar (the conditions of rule 2), the length of the
unsupported metal beyond the face of the die must not
exceed the diameter of the bar. https://www.youtube.com/watch?v=-CT3230Vszw
Forging

Automatic Hot Forging

• Slabs, billets, and blooms can be slid into one

end of a room and hot-forged products can
emerge at the other end, with every process
automated
Forging
Roll Forging

• Round or flat bar stock is reduced in

thickness and increased in length
• Produces products such as axles, tapered
levers, and leaf springs
• Little or no flash is produced

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Forging
Swaging

• Also known as rotary swaging and radial

forging
• Uses external hammering to reduce the
diameter or produce tapers or points on
round bars of tubes
Forging

Net-Shape and Near-Net-Shape Forging

• 80% of the cost of a forged-part can be due to post-forging
operations

• To minimize expense and waste, parts should be forged as

close the final shape as possible

• These processes are known as net-shape or precision forging