Rolling and Forging Manufacturing Processes Outline Temperature Rolling
- Slides: 85
Rolling and Forging Manufacturing Processes
Outline Temperature Rolling Flat Rolling Shape Rolling Operations Thread Rolling Seamless Tubing and Pipe Rolling Nonmetallic Materials Forging Open-Die Forging Closed-Die Forging Roll Forging Heading Rotary Swaging Forging Machines Dies Economics
Rolling and Forging Rolling The thickness of a slab or plate is reduced by cylindrical rolls which rotate to pull the material between them and compress it Forging A workpiece is compressed between opposing dies so that the material is forced into the die shape
Temperature in Metal Forming Cold working (room temperature or slightly higher) Warm working (30% - 50% of the melting temperature) Hot working (50% - 75% of the melting temperature) Isothermal forming Tools are preheated to prevent surface cooling during forming
Structure/Property Modification
Cold Working Advantages - No heating required - Better surface finish - Better dimensional accuracy - Parts are interchangeable - Better strength, fatigue and wear properties - Directional properties can be imparted - Minimal contamination problems
Cold Working Disadvantages - Higher forces required - More powerful equipment required - Less ductility is available - Surfaces must be clean - Intermediate anneals may be needed to restore ductility - Directional properties may be detrimental - May produce undesirable residual stresses
Typical Rolled Products
Typical Rolled Products
Rolling Process
Rolling Process
Rolling Process
Rolling Process
Rolling Process
Example of a Hot Rolling Line
Rolling Defects
Shape Rolling Uses a series of specially shaped rolls to form a beam with a specific cross section (such as an I-beam)
Ring Rolling Uses rolls to form a thick, smalldiameter ring into a thin, largerdiameter ring
Ring Rolling
Thread Rolling Uses moving dies with grooves to form threads on cylindrical parts
Thread Rolling
Material Property Changes
Roll Piercing Uses compressive stresses on a cylindrical part to cause tensile forces at the interior, creating a hole to form a thick-walled tube
Example of a Tube Rolling Mill
Rolling Nonmetallic Materials - Paper - Plastic sheets - Rubber products - Reinforced fabric Calendering Passes material through a series of gaps between rolls to form a thin sheet
Calendering
Calendering Example of a calendered rubber sheet with two layers Courtesy Cooper Tire
Calendering of Rubber
Coated Products
Reinforced Materials Coating on both sides of reinforcing material spools comb reinforcing material coating material windup coating material
Reinforced Materials Example of a polyester-reinforced rubber sheet with fibers exposed Courtesy Cooper Tire
Reinforced Materials Example of a steel-belted rubber sheet with the belt exposed Courtesy Cooper Tire
Calender Control Systems
Calendering Thickness Sensors Emitter X rays or beta radiation (electrons) some radiation is blocked, depending on thickness Detector
Milling Squeezes material between rolls to mix or preheat it for further processes
Forging A deformation process in which the material is compressed between dies, using impact or gradual pressure to form the part
Forging
Example of a Forging Machine
Example of a Forging Machine
Working Temperature Hot Forging Material is above its recrystallization temperature Cold Forging Increased strength from strain hardening
Forging Billet A piece of material with a square or circular cross section; usually produced by a deformation process such as rolling or extrusion
Open Die Forging Compresses the work between flat or nearly flat dies
Open Die Forging
Open Die Forging
Open Die Forging Advantages Simple, inexpensive dies; wide range of sizes; good strength Limitations Simple shapes only; difficult to hold close tolerances; machining necessary; low production rate; poor utilization of material; high skill required
Closed Die Forging Also called impression-die forging; compresses the material into the shape of the die cavity
Closed Die Forging
Closed Die Forging Advantages Good utilization of material; better properties than open die forging; good dimensional accuracy; high production rate; good reproducibility Limitations High die cost for small quantities; machining often necessary
Roll Forging Uses grooved rolls to reduce thickness and increase length of round or flat bars
Roll Forging
Roll Forging
Roll Forging
Coining Uses dies to press fine detail into both sides of the workpiece
Upsetting/Heading Decreases the length and increases the diameter of the workpiece; often used to form heads on nails, bolts, etc.
Orbital Forging Uses a die that moves in various directions to compress the workpiece
Swaging Uses hammering dies to decrease the diameter of the part
Swaging
Forging Dies and Die Inserts Separate inserts may be used forging complex shapes; this may be less expensive than a complex single-piece die
Forging Defects
Forging Machines
Forging Machines
Example of a Forging Machine
Economics
Metal Forging Chapter 3. 13
http: //www. mefos. se/images/forging. jpg
Open die video Both videos are from the Forging Industry Association http: //www. forging. org/facts/f Closed Die videoaq 9. htm http: //www. sciencemuseum. org. uk/on-line/challenge/making
Impression Die Forging Process Operations http: //www. forging. org/facts/idproc. htm
1. Forward extrusion reduces slug diameter and increases its length to produce parts such as stepped shafts and cylinders. 2. In backward extrusion, the steel flows back and around the descending punch to form cup-shaped pieces. 3. Upsetting, or heading, a common technique for making fasteners, gathers steel in the head and other sections along the length of the part.
We produced con-rod's forging mold with a main bearing hole in its large end, so as to the 'metal flow' runs along con-rod's entire body. And with a use of special material, we succeeded in producing con-rod with extreme intensity and durability. http: //www. tomei-p. co. jp/_2003 web-catalogue/e 060_conrod
The door hinge assembly, shown in Figure 6 -4, is currently the only instance of a forged aluminum door hinge for a production North American automobile. It is used on a high performance sport car. Since the hinge is critical to occupant safety, it meets all requirements of Federal Motor Vehicle Safety Standard 206, which applies to door locks and door retention components. The hinge assembly additionally meets the vehicle manufacturer's internal standards for life cycle requirements and door sag. Life cycle requirements were verified by 35, 000 cycles of testing over a wide temperature range. The door sag requirements were verified by deflection testing using prototypes machined from forged blocks. The forged aluminum hinge replaced a cast steel design, reducing vehicle weight by 2 kg (4. 5 lb). Purchase price was reduced by 50%. Part of the cost reduction is attributed to the as forged surface quality of the forgings, which receive a powder coat without requiring any surface finishing. http: //www. forging. org/engineer/pdf/Case. Study_64. PDF
Bralla ASM Metals Handbook Vol. 9 http: //www. heungkuk. co. kr/hk_eng_prod_
ASM Metals Handbook Desk Edition
ASM Metals Handbook Vol. 20 Materials Selection and Des
Summary Rolling and forging shape parts by deforming the material into the desired shape
- Forming and welding mcq
- Hot rolling
- Rolling load equation
- Rolling
- Hot rolling
- Hot rolling vs cold rolling
- Manufacturing cost vs non manufacturing cost
- Process costing vs job costing
- Commited cost
- Manufacturing cost vs non manufacturing cost
- Additive manufacturing steps
- Manufacturing processes for engineering materials 5th
- Classification of production system
- Introduction to manufacturing process
- Composite manufacturing process
- Nontraditional manufacturing processes
- Traditional manufacturing processes
- The transition to new manufacturing processes
- Fundamental manufacturing processes
- Concurrent in os
- Difference between curie temperature and neel temperature
- Difference between curie temperature and neel temperature
- Difference between curie temperature and neel temperature
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- Forging defects, with images pdf
- Parting line in forging
- Forging vs casting pros and cons
- Teknik pembentukan
- Pengertian forging
- Bulk deformation and sheet metal forming
- Flashless forging process
- Flashless forging process
- Flashless forging process
- Barreling in forging
- Flashless forging process
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- Sticking friction in forging
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- Open die forging
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- Forging
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- Machine design
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- Rolling torque and angular momentum
- Rolling torque and angular momentum
- Tools for mixing blending straining and rolling
- A broad and flat or gently rolling area
- Rolling torque and angular momentum
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- Rolling and extrusion
- Extrusion ratio
- "sensor wafer" and "manufacturing"
- Benefits of ict in design and manufacturing
- Jit lean manufacturing
- "klatencor" "manufacturing"
- Manufacturing and service technologies
- Manufacturing planning and control
- Manufacturing models and metrics
- Finished goods t account
- Wood manufacturing and finishing
- Difference between manufacturing and service operations
- Group technology and cellular manufacturing
- Minnesota mining and manufacturing post-it
- Managing service and manufacturing operations
- Managing service and manufacturing operations
- Manufacturing systems modeling and analysis
- Global manufacturing and supply chain management
- Comparing merchandising and manufacturing activities
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- Additive and subtractive modeling
- Synchronous manufacturing and theory of constraints
- Study of behavior and mental processes
- Wharton mdp
- Algo and amal
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- Process materials by hand with hand tools
- Reversible and irreversible processes in thermodynamics