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(a): Two high rolling mills In two high non reversing mills as two Since the rolls run in one direction only a
rolls which revolve continuously in same much less powerful motor and
transmission system is required. The rolls backup rolls for rolling hard in materials. extrusion by the use of spider die. Large
of a three high rolling mills may be either It may be necessary to employ work rolls diameters, thin walled, tubler products
plain or grooved to produce plate or of a very small diameter but of with execellent concentricity and
sections respectively. considerable length. In such cases tolerance charasitic can be produced.
adequate of the working rolls can be Types of extrusion:
3: Four high rolling mill:
obtained by using a cluster mill.
1: Direct extrusion or forward extrusion
It has a roll stand with four parallel rolls
one above the other. The top and the 2: Indirect extrusion or backward
bottom rolls rotate in opposite direction EXTRUSION extrusion
as do the two middle rolls. The two middle
Extrusion is the process of confining the FORGING
are smaller in size than the top and metal in a close cavity and then allowing it
bottom rolls which are called backup rolls to flow from only one opening, so that the Forging is the operation where the metal
for providing the necessary rigidity to metal will take the shape of the opening. is heated and then a force is applied to
the smaller rolls. The operation is identical to the manipulates the metals in such a way that
sequeezing of toothpaste out of the the required final shape is obtained.
A four high rolling mill is used for the hot Forging is generally a hot working process
toothpaste tube.
rolling of armor and other plates as well through cold forging is used sometimes.
as cold rolling of plates, sheets and By the extrusion process, it is possible to
make component which have a constant Type of forging
strips.
cross section over any length as can be 1. Smith forging
4: Tandem rolling mills: formed by the rolling process.
2. Drop forging
It is a set of two or three stands of roll Compexity of parts that can be obtain by
set in parallel alignment. So that a extrusion is more than that of rolling, 3. Press forging
continuous pass may be made through because the die required being very
4. Machine forging
each one successively with change the simple and easier to make. Also extrusion
direction of material. is a single pass process,unlike rolling the 1: Smith forging
amount of reduction that si possible in
This is the traditional forging operation
5: Cluster rolling mills: extrusion is large. Generally brittle
done openly or in-openly dies by the
materials can be very easily extruded. It
It is a special type of four high rolling mill village black smith or modern shop floor
is also possible to produce sharp corners
in which each of the two working rolls is by manual hammering or by the power
and different angles. It is possible to
backup by two or more of the larger hammer. The process involves heating the
gets shapes with internal cavaties in
stock in the black smith hearth and then typical products obtained in drop forging was develop for making bolts head in a
beating it over the anvil. To get the are cranks, crank shaft, connecting rods, continuous fashion, but now there are
desire shape the operator has to wrench, crane hooks etc. The types of fairly large number of diverse.
manipulate the component in between the operations are fullering, edging, bending,
Uses of this process:
blows. blocking, finishing and trimming etc.
Because of the beneficial grain flow
The types of operation available are 3: Press forging
obtain from upsetting. It is used for
fullering, flattering, bending, upsetting
Similar to the drop forging, the press making gears, blanks, shafts, excels, and
and swaging.
forging is also done in closed impression similar parts. Upsetting machine called up
2: Drop forging dies with the expectation that the force setter are generally horizontal acting.
is continuous squeezing type applied by The die set consists of die and
Basic definition:
the hydraulic press. Press forging dies corresponding punch or a heading tool.
This is the operation done in closed are similar to drop forging dies as also The die consists of two parts, one called
impression dies by means drop hammer the process in press forging, the metal is the stationary gripper die which is fixed
here the force for shaping the component shaped not by means of a series of blows to the machine frame and the other
is applied in a series of blows. as in drop forging , but by means of a movable gripper die which moves along
single continuous squeezing action. This with the die slide of the up setter. The
squeezing is obtained by means of stock is held then between these two
Drop forging utilizes a closed impression hydraulic presses. Because of the gripper dies.
die to obtain the desire shape of the continuous action of by hydraulic presses,
The upset forging cycle start with the,
component , the shaping is done by the the material gets uniformly deform
movable die sliding against the stationary
repeated hammering given to the material through out its entire depth ,the press
die to grip the stock. The two dies when
in the die cavity. The equipment use for forging dies with the various impression ,
in closed position from the necessary die
delivering for blows are called drop such as fuller, bender and finisher
cavity then the heading tool advance
hammers. The drop forging die consists impression properly arranged .
against the stock and upset it to
of two halves. The lower halve of the die 4: Machine forging: completely filled to the die cavity.
is fixed to the anvil of the machine, while
the upper halve is fixed to ram. The Unlike the press or drop forging where Having completed the upsetting the
heated stock is kept in the lower die, the material is drawn out, in machine heading tool moves back to its back
while the ram delivers 4-5 blows on the forging the material is only upset to get position. Then the movable gripper die
metal spreads and completely fills in the the desire shape. As it involves the releases the stock by sliding backward.
die cavity. When the two die of halves upsetting operation some time it is simply Similar to drop forging it is not possible
closed the complete is formed. The called as upset forging. Originally this to get the final shape in a single pass in
machine forging also. Therefore the
operation is carried out in number of
stages. The die cavities is required for
the various operations are all arrange
vertically on the gripper dies. The stock
is the move from stage one to another in
proper sequence till the final forging is
ready. A heading tool each for every
upsetting stage is arranged on the
heading slide of the upsetting machine.