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    Week9 Metal Forming

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    ebuka onwunyirigbo

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    Week9 Metal Forming

    Uploaded by

    ebuka onwunyirigbo
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    Copyright:

    © All Rights Reserved
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    20 views29 pages

    Week9 Metal Forming

    Uploaded by

    ebuka onwunyirigbo

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 29

    Semester 1 2023

    AME7009
    Mechanics, Materials and Manufacturing
    #9: Metal Forming

    Module Leader
    Dr Ma Mohin
    Lecturer in Mechanical Engineering

    SCAN Me for Moodle Link


    Contents

    1. Metal forming processes and its purpose


    2. Classification of metal forming
    3. Application of metal forming process
    4. Advantages and disadvantages of different metal forming process
    5. Examples and applications of forged parts in industry
    6. Various operations carried out in sheet metal forming and its applications
    7. Various types of casting processes
    Introduction to Metal Forming

    In Metal Forming
    ➢ The desired shape and geometry
    of part are achieved by
    deforming the matter plastically
    ➢ The properties of the material
    have been considered for
    material deformation
    Classification of Metal Forming
    Classification of Sheet Metal Working
    Bulk Deformation

    In Bulk deformation
    ➢ Workpiece undergoes plastic
    deformation
    ➢ Shape or cross-section changes
    ➢ Plastic deformation is much
    larger than elastic deformation
    ➢ Springback after deformation is
    negligible
    Forging

    In Forging
    ➢ Workpiece compressed between two
    dies
    ➢ Impact load or gradual load is used
    ➢ workpiece gets deformed to the die
    geometry
    ➢ Hot or cold condition is used
    ➢ High strength components are
    produced for aerospace, automotive,
    and other industries
    Classification of Forging

    Also known as
    Impression Die Forging

    Upset Forging (within closed


    die forging)
    Rolling

    In Rolling
    ➢ Plates or slabs are compressed
    between two rotating rolls
    ➢ The thickness of the workpiece
    is reduced
    ➢ Hot or cold condition is used
    ➢ Final product is sheet
    Classification of Rolling
    Extrusion

    In Extrusion
    ➢ Workpiece is compressed
    through a narrow opening of
    constant or varying cross section
    ➢ Hot or cold condition is used
    ➢ Products such as tubes, shafts,
    etc.
    Classification of Extrusion
    Wire Drawing

    In Wire Drawing
    ➢ Backward extrusion takes place
    ➢ Small diameter wires are
    produced from rods
    ➢ Workpiece diameter is reduced
    and length is stretched using its
    tensile properties
    ➢ Seamless tubes are also
    produced
    Cold, Warm and Hot Forming
    Processes

    Cold Working processes


    ➢ takes place under room temperature or slightly above
    ➢ Advantages:
    ▪ Better surface finish
    ▪ Closer tolerance
    ▪ No extra cost for furnaces, fuel, electricity, etc.
    ▪ Minimised machining requirement
    ➢ Disadvantages:
    ▪ Higher forces and power requirement
    ▪ Not enough ductile material could be formed
    ▪ Annealing of workpiece could be required
    Cold, Warm and Hot Forming
    Processes

    Warm Working processes


    ➢ Takes place at slightly above the room temperature
    but below the recrystallization temperature of the
    workpiece
    ➢ Advantages:
    ▪ Lower forces are required compared to Cold Working
    ▪ Intricate workpiece geometry is possible
    ▪ Annealing stages can be reduced as compared to
    Cold Working
    Cold, Warm and Hot Forming
    Processes

    Hot Working processes


    ➢ Takes place above recrystallisation temperature
    ➢ 70%-75% of the melting temperature is recommended
    ➢ Advantages:
    ▪ Significant deformation of workpiece can be achieved
    ▪ Lower forces are required
    ▪ Workpiece with premature failure can be hot formed
    ▪ Strengthening of workpiece may not be required
    ➢ Disadvantages:
    ▪ Poor surface finish
    ▪ Shorter tool life
    ▪ Lower dimension accuracy
    Applications of Forged Parts

    Some of the applications are


    ❑ Automotive: connecting rod, etc.
    ❑ Valves and fittings
    ❑ Hardware and hand tools
    ❑ Shipbuilding: drive shafts, etc.
    ❑ defence: shells and heavy
    artillery, etc.
    ❑ Aerospace: landing gear
    cylinders, etc.
    Sheet Metal Forming

    Sheet Metal Forming


    ➢ Is used to produce large quantities of
    sheet metal parts in desired shapes,
    geometries and sizes
    ➢ Involves a set of tools such as
    pneumatic or hydraulic press, punch
    and dies, for applying tensile and shear
    forces
    ➢ Common materials: low carbon steel,
    aluminium, titanium, etc.
    ➢ Is very popular in automotive,
    aerospace, consumer goods.
    Examples of Sheet Metal Forming
    Stamping

    In Stamping Sheet or Pressing


    ➢ Flat metal sheets converts
    into specific shapes
    ➢ Tool and die are used
    Examples of Stamping
    Casting

    In Casting
    ➢ Molten metal is introduced into a cavity
    and mould of the desired shape
    ➢ Material flows into the corners, fills the
    void and solidifies
    ➢ Reduction in volume (2% to 9 %) takes
    place due to solid being denser
    ➢ Appropriate provision needs to be made
    while making mould in order to obtain the
    correct dimensions of the part
    ➢ Usually, no need for joining or assembling
    for final part
    Casting Defects
    Sand Casting Process

    Sand Casting process


    I. Desired shape is put in a box and sand
    (mixed with clay) is poured
    II. Sand is then packed properly
    III. box is turned upside down, opened in two
    parts and then the shape is removed to
    create a mould with desired cavity
    IV. Molten metal is poured through it to be
    cavity and it solidifies
    V. Sand is removed to get the required casted
    part
    Permanent Mould Casting

    In Permanent Mould Casting


    or Gravity Die Casting
    ➢ Molten metal is poured into a
    metallic mould
    ➢ Mould are generally made up of
    cast iron or steel which are not
    destroyed or rebuild after every
    casting
    Die Casting

    In Die Casting
    ➢ A small portion of molten metal
    is poured and pushed into the
    mould with high pressure to
    spread across every part of the
    cavity to form the desired shape
    Centrifugal Casting

    In Centrifugal Casting
    ➢ Molten metal is poured in a
    mould and allowed to solidify
    while the mould is revolving
    ➢ Centrifugal force causes the
    metal to take up the impression
    of the mould cavity before it
    solidifies
    ➢ Mould is removed and the
    product is revealed
    Summary

    ✓ Why metal forming process is used in industry.


    ✓ Various applications of part produced through metal forming
    process.
    ✓ Difference between open and closed die forging.
    ✓ Difference between forward and backward extrusion.
    ✓ Difference between cold, warm and hot working.
    ✓ Types of casting and associated defects.
    Thank you
    Any Questions?

    @BoltonEng

    SCAN Me for Moodle Link

    29

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