Faculty of Engineering – Cairo University

Mechanical Design and Production Engineering

Two Semesters System – 3rd Year
Metal Forming Technology – MDP 310

Part II

Rolling & Extrusion Case Study

Submitted To
Prof. Abdallah Abdelkawy

Prof. Alaa El-Mokadem

Prepared by

Name BN ID
Mahmoud Ahmed El-Sayed Kassab 24 14710020170321

June 3, 2020
Introduction

Metal forming is a technique in which a material having a relatively simple geometry is

plastically deformed in one or more sequential operations to make a part of complex configuration.
Metal forming processes encompass a group of manufacturing methods by which a material,
usually shapeless or of a simple geometry, is transformed into a useful part, without change in the
mass or composition of the material. Metal forming includes many manufacturing processes which
can be classified into two categories: bulk forming operations like forging, upsetting, drawing and
sheet metal forming like stretch forming and deep drawing. This process helps to produce a
component with superior mechanical properties, with a minimum or no wastage of material,
resulting in considerable savings. Forming produces items that find a significant amount of
applications in automobile, aeronautical, industrial, defense components and consumer goods.

There is huge variety of methods for forming sheet metal. However, no conventional production
methods can compete with the output efficiency of roll forming. Today about 8% of cold rolled
and a small proportion of hot rolled sheet metal is roll formed, and output continues to increase
year on year.

The process of extrusion is most used for the manufacture of solid and hollow sections of
nonferrous metals and alloys. Aluminum is an extremely good material for metal extrusion.
Copper, magnesium, zinc, tin, and some softer low carbon steels can also be extruded with little
complication due to the material. High carbon steels, titanium, and various refractory alloys can
be difficult to extrude. [1]
Rolling Process

Roll forming can be defined as a progressive shaping and bending process, working in
several steps. During these steps, the sheet steel coils – typically within the range of 0.4 to 10
mm thickness - are shaped into a profile with a predetermined cross-section prior to cutting to
length. A typical production line for roll forming can produce products at a speed of 30–60
m/min.[2]

Rolling Case Study

Making Steel Strips for upcoming stamping process

process parameters:

Material: flow curve defined by 𝑌𝑓 = 350ε.19 working temperature: room temp

number of stages in case of rolling =1

W= 200mm ℎ0 =20 mm rollers radius = 200 mm ℎ𝑓 =16 mm

Friction coeff. between the rolls and the work is assumed to be 0.15 roll speed of 40 rev/min

d = 20-16 =4 mm

the maximum reduction for the given coefficient of friction is dmax = (. 15)2 (200)= 4.5mm
Since the maximum allowable reduction is bigger than the attempted reduction, the rolling
operation can be achieved . To compute rolling force, we need to know the contact length L and
the flow stress 𝑌𝑓 .

350∗(.22).19
𝐿 = √200 ∗ (4) =28.28mm ε = ln 20/16 = 0.22 𝑌𝑓 = =220.58 MPa
1.19

Rolling force is determined from F = 220.58*(200)*(28.28) = 1247.6 KN

Rolling General Operating Conditions
It remains to describe the conditions under which roll forming is carried out. The operating
conditions will be described under three headings:
Roll lubrication:
The decision whether to use a lubricant and, if so, about the type of lubricant and the method
of application, must be given careful consideration on the basis of the type of material being
rolled, the rolling speed, and the tooling material.
Roll quality and variation in material properties:
Two factors, which contribute to the sectional quality but are difficult to accommodate within
the tooling design, are the roll quality and the variation in material properties. Roll form tooling
is necessarily designed on assumptions regarding the material being formed. In practice the
material properties will vary from these nominal values, so the finished section for the same
tooling will alter.
Roll setting:
The setter, the person who sets the rolls on the mill, provides the link between the design and
development of tooling and the finished section production. The importance of roll setting
should not be underestimated — a good setter can salvage a poor design and can suggest those
minor modifications to the design that will improve the final section quality. Similarly, the
quality of roll design can become irrelevant if the rolls have been set carelessly.

Rolling Advantages
 Energy: efficiency Roll forming is an energy efficient process usually requiring no process
heat to be added.
 Material: almost any bendable material can be roll formed.
 Production: the high speed, continuous nature of roll-forming lends itself to economic
production of large volumes of parts.
 Structural Applications: roll formed materials generally have a strength advantage over
competing processes in structural rigidity applications.
 Tolerances: roll forming can achieve closer tolerances than are possible with most
competing processes.
 Tooling: the same tooling can be used to roll a shape out of different materials.
 Uniformity: roll-forming produces symmetrical parts with uniform dimensions that assure
precision fits, simplify production, and that speed assembly and minimize rejects.
Rolling Limitations
 Experienced roll design engineers must design those rolls designed for complex shape
forming.
 Complicated tubular shapes, and some closed shapes, may need mandrels to form the shape
accurately.
 Delicate, breakable, machine parts may need recurrent replacement during high volume
production runs.

Applications
 Hot rolled product such as concrete reinforcing bars, plates, wire rods, sheet and strip, rails,
structural.
 When the plates, sheet and strip products are used to manufacture of piping and tubes, body
panels and construction materials.
 Cold rolled product such as wire sheet and strip. The wire is often used in manufacturing
of cold form such as bolts and screws.
 The cold rolled sheet and strip used in automotive industries for external application such
as electrical motors, doors and more.
 Extrusion Process

Extrusion is a process in which the metal is subjected to plastic flow by enclosing the metal
in a closed chamber in which the only opening provided is through a die. The material is usually
treated so that it can undergo plastic deformation at a sufficiently rapid rate and may be squeezed
out of the hole in the die. In the process the metal assumes the opening provided in the die and
comes out as a long strip with the same cross-section as the die-opening. Incidentally, the metal
strip produced will have a longitudinal grain flow.[3]

Extrusion Case Study

Aluminum cans [4]

process parameters

material: Aluminum working temperature: room temp

type: impact extrusion direction: backward extrusion

Press required for the extrusion process: hydraulic backward horizontal impact extrusion press model (X150S)

stroke height: 330mm

maximum force on ram: 1500 KN

Extrusion General Operating Conditions
Direct or Forward Extrusion

In manufacturing industry, extrusion processes can be classified into two main categories,
direct and indirect. Hollow extrusions, as well as cross sections, can be manufactured by
both methods. Each method, however, differs in its application of force and is subject to
different operational factors.
In Direct or forward extrusion, the work billet is contained in a chamber. The ram exerts
force on one side of the work piece, while the forming die, through which the material is
extruded, is located on the opposite side of the chamber. The length of extruded metal
product flows in the same direction that the force is applied.

Backward or Indirect Extrusion

Indirect extrusion is a metal extrusion process in which the work piece is located in a chamber
that is completely closed off at one side. The metal extrusion die is located on the ram, which
exerts force from the open end of the chamber. As the manufacturing process proceeds, the
extruded product flows in the opposite direction that the ram is moving. For this purpose, the
ram is made hollow, so that the extruded section travels through the ram itself. This
manufacturing process is advantageous in that there are no frictional forces between the work
piece and the chamber walls. Indirect extrusion does present limitations. Tooling and machine
set up are more complicated, hollow rams are not as strong and less ridged and support of the
length of the metal extrusion's profile, as it travels out of the mold, is more difficult.

Extrusion Advantages
 Raw material savings of up to 90%.
 Reduced machining times up to 75%.
 Elimination of secondary machining operations.
 Reduction in multi-part assemblies.
 Improved mechanical properties for material strength and machining due to cold working
of the material.
 Significantly reduced total part costs up to 50%.
Extrusion Limitations
 High force requirement due to friction.
 Butt end left inside the cavity.
 The force required to push the ram changes as the punch moves.
 Billets needs preparing by tapering one end to match the die entry angle.
 Extrusion Defects: Surface cracking, Piping, and Internal Cracking.

Applications
 Aluminum extrusion are used in commercial and domestic buildings for window and
door frame, roofing and exterior cladding, shop fronts.
 Small products that achieved in cold extruded like collapsible tubes, aluminum cans,
cylinders, gear blanks.
 Tubes extrusion with all possible shapes.
Conclusion

The forming quality of the bite zone is the worst in the whole cold roll forming process. The
analysis of the layered distribution of sheet shows that the external layer is mainly subject to
tensile stress, while the internal layer is mainly subject to compressive stress, and the internal
layer residual stress is slightly larger than the external layer.
In order to save costs, one forming pass can be used to shaping the short edge of the target
product. However, this design method is suitable for those shape and dimension accuracy are not
very good. This design method is suitable for those products that do not require high quality at
the short edges. For the high quality and accuracy dimension products, more forming passes are
needed for the short edge forming.
For long edge forming of the target product several forming passes are needed to avoid the
dangerous area and keep the dimension accuracy.
As for extrusion it’s not hidden that its around us in our lives in daily used life products and this
manufacturing process made the production process of those products much easier and faster
which means affected the productivity so this caused to made these products cost effective.
Reference

[1] V. N. Danchenko, “NATIONAL METALLURGY ACADEMY of UKRAINE,” 2007.

[2] L. Troive and L. Ingvarsson, “Roll forming and the benefits of ultrahigh strength steel,”
Ironmak. Steelmak., vol. 35, no. 4, pp. 251–253, 2008.
[3] Anon, “Cold Forging and Extrusion.,” Eng., vol. 218, no. 9, pp. 855–859, 1978.
[4] T. H. E. Aluminum, E. Process, and B. W. Aluminum, “EXTRUSION,” 1886.
 Faculty of Engineering – Cairo University
Mechanical Design and Production Engineering
Two Semesters System – 3rd Year
Metal Forming Technology – MDP 310

Rolling & Extrusion Forming

(Brief & Selected Case Study Products)

Submitted To
Prof. Alaa El-Mokadem

Prof. Abdallah Abdalfattah

Prepared by
Name ID Seat Number B.N
Ayman Hisham Mahmoud Ahmed 14710020130367 73510 10

June 4, 2020
Introduction

Metal forming is the final stage of metallurgical manufacturing permitting to produce metal
ware used in national economy as the finished products or as the billet for further processing. Metal
forming is the main method of making metal products and semi-finished products. More than 90%
of smelted metal is processed by different methods of metal forming.

Plastic properties of metals are used during the process of metal forming. That is the ability to
change without damage the shape and dimensions in hot and cold condition under the pressure of
machining tools. The knowledge of metal forming rules permits to realize the forming at optimum
deformation regimes and to use the appropriate main and auxiliary equipment. The variety of
methods and kinds of metal forming permits producing the wide range of metal products with high
productivity, exact dimensions, required mechanical properties.

Rolling is the most used and the most efficient type of metal forming, which consists in
deformation of metal by means of rotating rolls 75-80% of the total quantity of smelted metal is
being processed by rolling.

Extrusion is a compression process in which the work metal is forced to flow through a die opening
to produce a desired cross-sectional shape. There are many classifications for the extrusion
processes, it may classify depending on the extrusion direction as direct and indirect another
classification is by working temperature as cold or warm or hot extrusion.[1]
Metal Forming by Rolling

1. Process
In this process, the workpiece in the form of slab or plate is compressed between two
rotating rolls in the thickness direction, so that the thickness is reduced. The rotating rolls draw
the slab into the gap and compresses it. The final product is in the form of sheet.[2]

2. General Operating Conditions

Cold working: Generally done at room temperature or slightly above RT.

Warm working: In this case, forming is performed at temperatures just above room
temperature but below the recrystallization temperature. The working temperature is taken to
be 0.3 Tm where Tm is the melting point of the workpiece.

Hot working: Involves deformation above recrystallization temperature, between 0.5Tm to

0.75Tm.

General Rolling Processes

• Flat Rolling • Forging Rolling

• Shape Rolling • Skew Rolling

• Ring Rolling • Thread Rolling

3. Advantages
• High productivity.
• Close tolerances with excellent repeatability.
• Full automation, with other operations such as punching, sweeping, and welding integrated
into the process.
• Capability to produce an almost endless variety of complex profiles.

4. Limitations
• Small orders are more expensive.
• Tooling can be expensive, though this can be justified over the long term by savings in
labor cost per piece.
• The roll forming line needs to be setup by an experienced operator.
• Roll forming produces end flare due to linear stresses, an issue where one end of the part
flares outward.

5. Applications
• All structural shapes and rails.
• Bars and rods.
• Plates and sheets that used in varies industries.
 6. Case study application
Cold rolled strip : a popular metal product within the automotive industry, stamped into body
panels as well as other automotive components.

Material: 𝑌𝑓 = 275ε.15

Working temperature: room temp

Number of stages =1

W= 300mmwide ℎ0 =25 mm thick rollers radius = 250 mm ℎ𝑓 =22 mm thick

Friction coefficient between the rolls and the work is assumed to be 0.12 roll speed = 50 rpm

d = 25-22 =3 mm

the maximum possible draft for the given coefficient of friction is dmax = (. 12)2 (250)= 3.6mm
Since the maximum allowable draft exceeds the attempted reduction, the rolling operation is
feasible. To compute rolling force, we need the contact length L and the average flow stress 𝑌𝑓 .

275∗(.128).15
𝐿 = √250 (25 − 22) =27.4mm ε = ln 25/22 = 0.128 𝑌𝑓 = =175.7 MPa
1.15

Maximum Force By rolls (F) = 175.7(300)(27.4) = 1444254 N

Metal Forming by Extrusion

1. Process
Pressing is the method of product manufacturing by
means of metal extrusion through the die hole .It is
mainly used in non-ferrous metallurgy and aviation
industry where the shaped sections are produced from
such materials as Al- and Ti-based hard-to-deform and
low-plasticity alloys. Extrusion is a compression process
in which the work metal is forced to flow through a die
opening to produce a desired cross-sectional shape. [3]

2. General Operating Conditions

This can be part into two sections

1. Operating temp
Hot extrusion involves prior heating of the billet to a temperature above (0.5Tm). This reduces
strength and increases ductility of the metal, permitting more extreme size reductions and more
complex shapes to be achieved in the process. Additional advantages include reduction of ram
force, increased ram speed. Cooling of the billet as it contacts the container walls is a problem,
and isothermal extrusion is sometimes used to overcome this problem.

Cold extrusion and warm extrusion are generally used to produce discrete parts, often in
finished (or near finished) form. Some important advantages of cold extrusion include
increased strength due to strain hardening, close tolerances, improved surface finish, absence
of oxide layers, and high production rates. Cold extrusion at room temperature also eliminates
the need for heating the starting billet.
 2. Extrusion direction
• Direct Extrusion • Indirect Extrusion

the metal is placed in a container and driven the hollow ram containing the die is kept stationary

through the die by the ram. and the container with the billet is caused to move.

the dummy block or pressure plate is placed friction at the die only (no relative movement at the

at the end of the ram in contact with the billet. container wall) so requires roughly constant pressure

3. Advantages
• A variety of shapes are possible, especially with hot extrusion.
• Grain structure and strength properties are enhanced in cold and warm extrusion.
• Fairly close tolerances are possible, especially in cold extrusion.
• Little or no wasted material is created.

4. Limitations
• Center burst is an internal crack that develops because of tensile stresses along the
centerline of the work part during extrusion.
• Piping is a defect associated with direct extrusion. It is the formation of a sink hole in the
end of the billet.
• Surface cracking results from high work part temperatures that cause cracks to develop at
the surface. They often occur when extrusion speed is too high, leading to high strain rates
and associated heat generation.
 5. Applications
• Extrusion is widely used in production of tubes and hollow pipes.
• Aluminum extrusion is used in structure work in many industries.
• This process is used to produce frames, doors, window etc. in automotive industries.
• Extrusion is widely used to produce plastic objects.

6. Case study application

The Manufacturing of Collapsible Tubes [4]

Material Working Extrusion Type & Press required Stroke Hight Maximum
Temperature Direction Force on Ram
Aluminum Room Temperature Indirect Impact Hydraulic impact 254 mm 60 Tons
Extrusion extrusion press
Conclusion

The roll forming machine factory helps in creating high quality, precise and long lasting
metal pieces for various purposes. They are one of the best options because of its high efficiency,
cost-effectiveness, quick turnaround.

Each roll forming application type has its pros and cons, balancing cost, accuracy and throughput.
The faster and more accurate a system must be, the more expensive it is likely to be. Closed loop
systems are generally more accurate than open loop systems, but they are also more expensive.

Extrusion of aluminums are the most common in this industry as they are lightweight, strong,
corrosion resistant, fully recyclable. They utilize tailored alloys, accommodate complex shapes,
can incorporate multiple functions and are easy to fabricate, providing a custom design response
quickly and at minimal cost making aluminum extrusions the cost effective solution.
Reference

[1] G. Narayanan, “Metal forming processes Metal forming : Large set of manufacturing
processes in which the material is deformed plastically to take the shape of the die geometry
. The tools used for such deformation Categories : Bulk metal forming , Sheet metal
forming.”
[2] S. J. Mander, S. M. Panton, R. J. Dykes, and D. Bhattacharyya, “Chapter 12 Roll forming
of sheet materials,” Compos. Mater. Ser., vol. 11, no. C, pp. 473–515, 1997.
[3] O. Use, “Unclassified Limitation Changes To : From :,” Distribution, no. May, 1960.
[4] S. Anand and D. Mane, “Saurav Anand and Digambar Mane,” vol. 3, no. 2, pp. 391–398,
2014.