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FMP 221 Lecture 9 Cold Working

Cold working of metals involves plastic deformation below the metal's recrystallization temperature to improve properties. Major cold working operations include squeezing through rolling, swaging, riveting, and forging as well as bending, shearing, blanking, drawing, and ironing. Cold rolling passes metal through rollers to achieve the final size. Cold forging uses dies to reduce a workpiece's diameter. Riveting fastens metal pins by pressing or spreading them. Coining squeezes metal in confined dies to form intricate shapes.

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98 views34 pages

FMP 221 Lecture 9 Cold Working

Cold working of metals involves plastic deformation below the metal's recrystallization temperature to improve properties. Major cold working operations include squeezing through rolling, swaging, riveting, and forging as well as bending, shearing, blanking, drawing, and ironing. Cold rolling passes metal through rollers to achieve the final size. Cold forging uses dies to reduce a workpiece's diameter. Riveting fastens metal pins by pressing or spreading them. Coining squeezes metal in confined dies to form intricate shapes.

Uploaded by

SarojKumarSingh
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Lecture- 8

Cold Working of metals

Altering the shape or size of a metal by plastic


deformation.
Mechanical

working

recrystallisation

of

point

metals
usually

temperature.
Cold working is employed
Improved mechanical properties
Better machinability
Special size accuracy
Bright surface

below
at

the
room

The major cold-working operations are classified as


A. Squeezing
Rolling
Swaging
Riveting
Cold forging
Extrusion
Coining
Hobbing
B. Bending
C. Shearing
D. Blanking
E. Drawing

Roll bending
Seaming
Straightening

Stamping/Embossing
Ironing

Cold rolling
Cold rolling is a
metal
working
process in which
metal is deformed by
passing it through
rollers
at
a
temperature below
its recrystallization
temperature.
Passing unheated,
previously hot-rolled
bars, sheets or strip
(cleaned of scale)
through a set of
rolls, often many
times, utilize the
final
size
is
obtained.

Cold rolling mill

Rolling of stainless steel into thin sheet.

Cold forging or Swaging


The term swage can apply to the process of swaging,
a die used for swaging, or a tool used to swage.
It is basically a process for reducing the diameter,
tapering or pointing round bars or tubes by external
hammers.
It is done by means of a rotary swaging machine
consisting mainly a hollow spindle, which carries the
die sections and rollers.
The die is inserted in the slot in a spindle rotated and
forced together repeatedly by the rollers around the
periphery forming taper on the work.

Swaging is a forming method of reducing a


regular or irregular cross section area of tube,
bar or wire using two or more dies which
surround the outside of the workpiece
completely
or
partially,
to
a
round
predetermined diameter.
1 -

Head

2 -

Rollers

3 -

Backers

4 -

Motorized spindle

5 -

Dies

Operation of swaging
The dies rotate and apply a
radial force around the
workpiece toward its center.
The radial forces are applied
with short strokes and high
frequency.
The forming by swaging
converts kinetic energy into
impact energy and then into
forming forces, applied by the
die to the workpiece.

Riveting

It is a permanent fastening operation in which


the end of the metal pin is pressed over or
spread out by blow of the hammer.

Coining
Coining is the squeezing of metal while it is
confined in a closed set of dies.
A workpiece is placed a confined die.
A movable punch is located within the die.
The actions of this punch cold works the material
and can form intricate features.

Material is displaced to form specific shapes


in the part.
Coining typically should not exceed a depth
of 30 percent of the material thickness.
Requiring more force than normal deep draw,
this operation also requires strong, durable
tooling.
This process is used to produce coins,
medallions and other similar products on flat
stock with relief features.

It is a cold working process


that is used to form cavities
in the various types of dies,
such as those used for
moulding plastics.
A hob is a punch having an
outside contour similar to
that of the parts to be
moulded.
Like the punch, the hob is
pressed into the block of
steel.

Hobbing

Bending
It is the plastic deformation of metal about a linear
axis with little or no change in the surface area.
When two or more bends are made simultaneously
with the use of a die, the process sometimes called
forming.
Bending

1.Roll bending
2.Seaming
3.Straightening
4.Stamping

Roll bending
Plates, heavy sheets
and rolled shapes can
be bent to a desired
curvature on forming
rolls.
These
usually
have
three rolls in the form of
a pyramid, lower roll
being driven and the
upper roll adjustable to
control the degree of
curvature.

Seaming

A line of junction formed by sewing together two pieces


of material along their margins.
It is used to join ends of sheet metal to form containers
such as cans and drums.
The seams are formed by a series of small rollers on
seaming machine.

After
certain
processes, such as
rolling, extruding and
drawing, bars, tubes,
plates
and
sheets
usually require some
straightening
or
flattering.

Straightening

Straightening
and
flattering
machines
may be classified as
either
roller
or
stretching types.
The rollers bend the work piece in all appropriate
directions with a gradually increasing radius so that at
the exit end straightness is achieved.

Tube straightening

Shearing
The cutting and separating of
material without the formation
of chips.
Punching, piercing, lancing,
parting, notching, and shaving
are all shearing operations.
It is the mechanical cutting of materials in sheet or
plate form without the formation of chips or use of
burning or melting.
When the two cutting blades are straight, the process
is called shearing.

During the shearing process, an upper blade and a lower


blade are forced past each other with the space between
them determined by a required offset.
Normally, one of the blades remains stationary.

Blanking
Blanking is the operation of
punching,
cutting,
or
shearing a piece out of stock
to a predetermined shape by
die cutting the outside shape
of a part.
Blanking is a metal stamping
operation by which the sheet metal is
punched to get the required outer
profile of the sheet metal component.
During the blanking process the
blanking punch penetrates into the
sheet metal and forces the material
into the blanking die. The portion of
the sheet Metal which comes out
through the blanking die opening is
the component with the required
profile.

Blanking is a metal fabricating process, during which a


metal workpiece is removed from the primary metal strip
or sheet when it is punched.
The material that is removed is the new metal workpiece
or blank.

Drawing
It is similar to hot drawing but the higher
deformation forces, thinner metal and limited
ductility are the distinctive features.
When the depth of the drawn part is less than the
diameter or minimum surface dimension, of the
blank, the process is called as shallow drawing.
If the depth is greater than the diameter, it is called
deep drawing.

Drawing is the pulling of a metal piece through a die


by means of a tensile force applied to the exit side.
A reduction in cross-sectional area results, with a
corresponding increase in length.

Stamping/Embossing
Letters, numbers, or other figures can be produced
in the surface of sheet metal and other metal parts
by a process called "Stamping" which consists of
forging a hardened steel punch against the metal
surface.

Stamping is used to make high volume parts such as


aviation or car panels or electronic components.
Mechanical or hydraulic powered presses stamp out
parts from continuous sheets of metal or individual
blanks.
The upper die is attached to the ram and the lower die
is fixed.
Mechanical machinery transfers all energy as a rapid
punch, Whereas hydraulic machinery delivers a
constant, controlled force.

Ironing
Ironing is the name given to the process of thinning the
walls of the drawn cylinder by passing it between a
punch and die where the separation is less than the
original wall thickness.
Mechanical working is necessary in the manufacture of
all forms of metals except that, which is cast directly
into its finished shapes.
Many of the shapes or forms produced in a particular
process will be reshaped to some other forms in a later
process.
The final shape or form will frequently be the result of
sequence of operations.

Shot peening
Shot peening is a cold working process in which the
surface of a part is bombarded with small spherical
media called shot. The shot peening is done by air
blast. As the shot strikes, small indentations are
produced causing a plastic flow of surface metal to a
depth of few hundreds of a centimetre. The surface
is slightly hardened and strengthened.
Compressive stresses are beneficial in increasing
resistance to fatigue failures, corrosion fatigue,
stress corrosion cracking.

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