ENM208 BULK DEFORMATION - PROCESS 1 ANADOLU UNIVERSITY - Industrial Eng. Dep. +Bulk Deformation Processes in Metal Forming «Metal forming operations which cause significant shape change by deformation in metal parts whose initial form is bulk rather than sheet “Bulk" refers to workparts with relatively low surface area-to-volume ratios * Starting forms: cylindrical bars and billets, rectangular billets and slabs, and similar shapes + These processes work by stressing metal sufficiently to cause plastic flow into desired shape + Performed as cold, warm, and hot working operationsBulk Deformation Processes in Metal Forming c) Bulk deformation processes are performed as Cold, warm and hot working operations ® Cold and Warm working is appropriate when + Shape change is less sever; * There is a need to improve mechanical properties; + Achieve good surface finish on the part. ® Hot working is generally required when massive deformation of large workparts is involvedImportance of Bulk Deformation Processes @ When performed as hot working, they can achieve significant change in shape of the workpart. = When performed as cold working operations, they can be used not only to shape the product, but also to increase its strength. ® These processes produce little or no waste ™ Some bulk deformation operations are near net shape or net shape processes. ® They achieve final product geometry with little or no subsequent machiningFour Basic Bulk Deformation Processes { Rolling - slab or plate is squeezed between opposing rolls =—_> Forging - work is squeezed and shaped between opposing wo« dies — Extrusion — work is squeezed through a die opening, thereby taking the shape of the opening Wire and bar drawing — diameter of wire or bar is reduced by pulling it through a die opening bie ® eedUTE Cat ad Cl Rolling = Deformation process in which work thickness is reduced by compressive forces exerted by two opposing rolls F Roll Roll i —_—> v Direction of work flow Work Roll F (a) eedThe Rolls § The rotating rolls perform two main functions: + Pull the work into the gap between them by friction between workpart and rolls + Simultaneously squeeze the work to reduce cross section eedTypes of Rolling + By geometry of work: - Flat rolling - used to reduce thickness of a rectangular cross-section — Shape rolling - a square cross-section is formed into a shape such as an I-beam + By temperature of work: — Hot Rolling - most common due to the large amount of deformation required — Cold rolling — produces finished sheet and plate stockUTE Cat ad Cl Rolled Steel Products Intermediate rolled form Final rolled form Structural shapes Bloom oe g GZ Slab Coils — Plates, sheets aa” Billet Bars, rods x .- eedUTE Cat ad Cl Flat Rolling ® It involves the rolling of slabs, strips, sheets, and plates, workparts of rectangular cross section in which the width is greater than the thickness. Direction of work flow ——> Work eedFlat Rolling Analysis = Draft: The work is squeezed between two rolls so that its thickness is reduced by an amount called the draft. d =t,-t; d = draft; t, = starting thickness; and ¢; = final thickness where = Reduction: The draft is sometimes expressed as a fraction of the starting stock thickness, called the reduction Reduction= [| = — fo When a series of rolling operations is used, reduction is taken as the sum of the drafts divided by the original thicknessFlat Rolling Analysis @ Spreading: In addition to thickness reduction, rolling usually increases work width. This is called spreading ® Conservation of material is preserved, so the volume of metal exiting the rolls equals the volume entering: tyWyly =t w/b Where oor SOLS W, and w, are the before and after work widths (mm) L, and L, are the before and after work lengths (mm) a Similarly, before and after volume rates of materials flow must be the same, so the before and after velocities can be related: LyWoVo =f, W Vy Where v, and v, are the entering and exiting velocities of the workFlat Rolling Analysis | Maximum Draft: There is a limit to the maximum possible draft that can be accomplished in flat rolling with a given coefficient of friction nx = WR dinax = Maximum draft (mm). 11 = coefficient of friction R= roll radius (mm)Flat Rolling Analysis | Rolling Force: The rolling force can be calculated based on the average flow stress experienced by the work material in the roll gap F=YwL Where Y = average flow stress (MPa) wL = the roll-work contact area (mm?) - Contact length can be approximated by L= JRO, —t;) eedUTE Cat ad Cl Flat Rolling Analysis ®@ The torque in rolling can be estimated by assuming that the roll force is centered on the work as it passes the rolls and that it acts with a moment arm of one-half the contact length L. T=0.5FL = The power required to drive each roll is the product of torque and angular velocity P=27NFL F = rolling force (N) Where P = power (J/s) N = rotational Speed (rev/min) L = contact length (m)Shape Rolling @ Work is deformed into a contoured cross-section rather than flat (rectangular) @ Accomplished by passing work through rolls that have the reverse of desired shape ® Products include: — Construction shapes such as I-beams, L-beams, and U-channels — Rails for railroad tracks — Round and square bars and rodsRolling Mill Configuration Two-high — two opposing large diameter rolls Vv, . QQ. —_» f X (a) eedUTE Cat ad Cl Rolling Mill Configuration Three-high - work passes through both directions (b) eedRolling Mill Configuration Four-high — backing rolls support smaller work rolls eedRolling Mill Configuration Cluster mill — multiple backing rolls on smaller rolls (a)Rolling Mill Configuration Tandem rolling mill - sequence of two-high mills eedDUET Cea ed Thread Rolling + Bulk deformation process used to form threads on cylindrical parts by rolling them between two dies + Most important commercial process for mass producing bolts and screws + Performed by cold working in thread rolling machines + Advantages over thread cutting (machining): — Higher production rates — Better material utilization — Stronger threads due to work hardening Starting blank Finished part “ T a T a — =. o @) er Td Fixed dieRing Rolling + Deformation process in which a thick-walled ring of smaller diameter is rolled into a thin-walled ring of larger diameter + As thick-walled ring is compressed, deformed metal elongates, causing diameter of ring to be enlarged + Hot working process for large rings and cold working process for smaller rings + Applications: ball and roller bearing races, steel tires for railroad wheels, and rings for pipes, pressure vessels, and rotating machinery + Advantages: material savings, strengthening through cold working Idler roll Main roll FeedUTE Cat ad Cl Forging ® Forging is a deformation process in which work is compressed between two dies ® Oldest of the metal forming operations, dating from about 5000 BC 3 Components: engine crankshafts, connecting rods, gears, aircraft structural components, jet engine turbine parts In addition, basic metals industries use forging to establish basic form of large components that are subsequently machined to final shape and sizeClassification of Forging Processes @ Cold vs. hot forging: og Hot or warm forging — most common, due to the significant deformation and the need to reduce strength and increase ductility of work metal =} Cold forging - advantage is increased strength that results from strain hardening = Impact vs. press forging: Forge hammer - applies an impact load @ Forge press - applies gradual pressure eedClassification of Forging Processes = Another difference among forging operations is the degree to which the flow of the work metal is constrained by the dies. 1- Open-die forging operation. 2- Impression-die forging operation. 3- Flashless forging operation. eedOpen-die Forging Operation <) The work is compressed between two flat dies, thus allowing the metal to flow without constraint in a lateral direction relative to the die surfaces. \"" Upper die Workpiece Lower die (stationary) (a)