Mechanical Working Processes: Vinay Bhatt

This document is a property of L&T, Hazira Works and must not be copied and lent without their permission
in writing. 1
Pressing (Die & Point Pressing ,Spinning)
VINAY BHATT
Date: 23rd June 2006
Extrusion, Drawing & Bending
Mechanical Working Processes
This document is a property of L&T, Hazira Works and must not be copied and lent without their permission in writing. 2
FUNDAMENTALS-METAL FORMING
Classification of forming Processes
1. Direct compression
2. Indirect compression
3. Tension
4. Bending
5. Shearing
Typical forming operations

1. Forging
2. Rolling
3. Wire Drawing
4. Extrusion
5. Deep Drawing
6. Stretch forming
7. Bending
8. Shearing
Temperature in Metal Working.

1. Hot Working
2. Cold Working
3. Warm Working

% Cold Work
Annealing Temperature
Strength
Ductility
Strength
Ductility
Strain Hardening

Tensile Strength
Yield Strength
Elongation
Property
Reduction by Cold Work%
Residual Stresses

Compression Tension
Inhomogeneous Deformation in rolling of sheet
Resulting distribution of long. Residual stress over
thickness of sheet
Shell
Nozzle
Long. Seam
Circ. Seam
Dend
REACTOR CONSTRUCTION
Y.S AT HIGH TEMP.
0
5
10
15
20
25
30
35
40
45
50
3
8
6
6
9
3
1
2
1
1
4
9
2
0
4
2
6
0
3
1
6
3
4
3
3
7
1
3
9
9
4
2
7
4
5
4
4
8
2
5
1
0
5
3
8
6
0
0
6
5
0
7
0
0
Temperature (C)
Y
i
e
l
d

S
t
r
e
n
g
t
h

(
k
s
i
)
CS
C-0.5Mo
LAS (1.25
Cr-0.5 Mo)
LAS (2.25
Cr-1 Mo)
Hot forming
zone
DISH END FORMING
Crown & Petal
Hot forming
Cold forming
Single Piece
Hot forming
Cold forming
Spinning
Dend
Forming
SINGLE PIECE DISHEND
CROWN & PETAL DEND
Crown
Petals
Crow
n
Plate
Petal Plate
CROWN & PETAL DEND
TYPES OF DISH ENDS
1. Torispherical
2. Elliptical
3. Hemispherical
4. Flat heads
TORISPHERICAL DISHEND
Blank Dia.= 25/24(D)+2/3(K.R)+2(SF)
Where D =Dia of Dend
K.R=Knuckle radius
SF=Straight Face of Dend

TORISPHERICAL DISHEND
Seamless(one-piece head)
ELLIPTICAL DISHEND
Blank Dia.= /4(D+d)+2(SF)
Where D =Dia. of Dend in horizontal
d=Dia.of Dend in vertical

HEMISPHERICAL DISHEND
Blank Dia.= 8R(R+SF)
Where R =Radius of Dend
HEMISPHERICAL DISHEND
Spherical seamless head(ID 3.4mt., 92mmThk.,steel SA387 Gr 11)
FLAT HEADS
FLAT HEADS
Flat Head (OD 4.1mt,Knuckle radius 100mm)
PRESSING
Die Pressing
Point Pressing
Spinning

Die Pressing- Work piece in between the punch & Die
- Force applied over the whole area
- One time pressing
- High temp. pressing
- Stress generated < point pressing
- Cost Economics
- New die required every time for different
dimensions of work piece

DIE PRESSING
HOT FORMING OPERATION
HOT FORMING OPERATION
Circular Blank being removed out of furnace
HOT-DISHING PROCESS
Hot-Dishing process of a one-piece head Tori-spherical shape
HOT-DISHING PROCESS
Blank transferred to the 2500ton-hydraulic press
2500 MT HYDRAULIC PRESS
HOT-DISHING PROCESS
Blank positioned onto the forming ring
HOT-DISHING PROCESS
Ring being positioned within the operating press fitted with forming die
HOT-DISHING PROCESS
Circular blank being dished
HOT-DISHING PROCESS
Dished head being extracted out of the forming tools
TYPICAL PRESS
CONICAL PIECE
Conical transition piece (Dia-2.7mt.,height 1.35mt.,steel grade SA387 Gr11)
POINT PRESSING
Point Pressing- Pressing with punch
- Die not required
- Force applied only on local area
- Pressing at different points to gain the shape req.
- Cold pressing
- Stress generated > Die pressing
- Cost economics

COLD FORMING OPERATION
PUNCH
400MT HYADRAULIC PRESS
800MT HYADRAULIC PRESS
POINT PRESSING
POINT PRESSING
Max. Thickness pressed in L&T 70mm
DISHEND (DIA 16.3mt)
DISHEND
SPINNING
forming 3-dimensional symmetrical parts from flat circles of metal.
Economical alternative to stamping, casting and many other metal
forming processes.
Metal Spinning
MANUAL SPINNING
Types of Spinning
1. Manual Spinning
2. Power Spinning
Manual Spinning
-No appreciable thinning of metal.

-lathe- pressing -tool against a circular metal blank rotated by
headstock.

-Preheated metal -increase ductility & to reduce strength

Products- light reflector,tank ends,covers,housings,shields &
components for musical instrument.

MANUAL SPINNING
The practical max. thickness low Carbon Steel - 3.2mm
max. diameter - 1829mm

Advantages of Manual Spinning
1. Capital investment in equipment & tooling - small
2. Setup time - shorter
3. Design changes in the work piece - at min. expense.
4. Changes in work metal comp. or thk.- min. tool changes.

MANUAL SPINNING
a. Skilled operators -required
b. Slower than press forming
c. Force inadequate
Limitations of Manual Spinning
Tool Tool
Blank
Clamp
Manual Spinning
MANUAL SPINNING
Setup simple hand tool
MANUAL SPINNING
Products;
Flanges , rolled rims ,cups , cones & double-curved surfaces
of revolution bells.
Typical conical,cylindrical & dome shapes
POWER SPINNING
Cone
Roller
Blank
Shear Spinning
Power Spinning
-Shear Spinning
-Metal is intentionally thinned by shear force

-Forming (Sine Law) : T2=T1(Sin )
T2=Thk. spun work piece
T1=Thk.starting blank
= One-half apex angle
T2

T1
POWER SPINNING
Power spinning in a vertical machine
SPINNING
Products:
hardware items(metal tumblers) to large components for
aerospace application

-Conical & curvilinear shapes

-Blank dia . 240 in. ,thk. Upto 1 in. can be spun

POWER SPINNING
Effect Work metal properties
-Surface finish is good
-Tensile & yield strength increases
-Ductility decreases
-Hardness increases
EXTRUSION
Classification of Extrusion Process
1. Direct Extrusion
2. Indirect Extrusion
Extrusion: Block of metal reduced in X-section by forcing
through the die orifice under high pressure.
Die
Billet
Container
Ram
Direct Extrusion
Direct Extrusion

-Metal billet driven by ram
-Container stationary
Indirect Extrusion

Ram stationary
- Container moves
Billet
Container
Container
Ram
Indirect Extrusion
EXTRUSION
Extrusion Equipment

1. Hydraulic Vertical Extrusion Press(300-2000tons)
- Uniform Deformation
- Higher rate of production
- Need for less floor space
2. Hydraulic Horizontal Extrusion Press(1500-5000tons)
- Bottom of billet cools rapidly than top deformation will
be non-uniform
- Used for most commercial extrusion of bars & shapes
EXTRUSION
HOT-EXTRUSION
Variables influencing the force required to cause extrusion

1. Type of Extrusion
2. Extrusion Ratio
3. Working Temperature
4. Speed of deformation
5. Frictional condition at the die & container wall

Extrusion Pressure=(Ext.Force/X-sectional Area Billet)

HOT-EXTRUSION
Extrusion ratio(R ) =Initial X-section Area of the Billet = Ao
Final X-sectional Area of the Billet Af

P=k Ao ln R ; where P=Extrusion force, k=Extrusion constant

Ram Travel,in
Direct Extrusion
Indirect Extrusion

Advantage of Hot Extrusion

-Decrease in flow stress or deformation resistance

Limitation of Hot Extrusion
-Problem of oxidation of billet & the extrusion tools
-Softening of the die & tools
-Problem to provide adequate lubrication
Top working Temp. should be below the melting point or
hot shortness range.
HOT-EXTRUSION
HOT-EXTRUSION
Billets heated to a temp 1100-1200C

Preheat temp. of tools 350C

Extrusion Pressure-125000-180000psi.
Hot Extrusion of steel
HOT-EXTRUSION
Ram Travel Speed & Extrusion Pressure

-Travel speed of ram extrusion pressure

-Low speed cooling of billet flow stress

-Temp. rise lead to hot shortness
HOT-EXTRUSION
Work piece temp.
Strain Rate
Solidus Temp.
P3
P2
P1
P1<P2<P3
#With increase in temp.,flow stress falls - deformation Increases.
#Limit to temp scale is the solidus or hot-shortness Temp.
HOT-EXTRUSION
Mechanism for softening

-Dynamic Recovery
-Dynamic Recrystallization

Deformation,Lubrication & Defects
Homogeneous Deformation Increased Friction
Extremely high friction
DEFECTS
Surface Cracks -Discontinuous film of lubricant

Internal Oxide Stringer- Dead metal zone(containing oxides)
extruded toward the center.

To avoid this type of defect :

1. Discard the billet -surface oxide begins to enter the die.

2. Use follower block.
DEFECTS
Fir-Tree Cracking
- Due to longitudinal stresses
- Intergranular - associated with hot shortness
- Too high a ram speed for the extrusion temperature.

Center Burst(Chevron cracking)
- Frictional condition on the zone of deformation at
the extrusion die.
EXTRUSION

Cold Extrusion
-Good dimensional control & good surface finish.

-Spark plug bodies,shaft,pins & hollow cylinders or cans.
Extrusion of tubing
-Mandrel fastened - end of extrusion ram

-Thickness of the tube -Clearance between the mandrel & the die
TUBE EXTRUSION

Billet

Billet
Piercing Mandrel
Piercing
Extrusion
DRAWING
-Pulling of metal through a die.
-Compressive force - reaction of metal with die.
-Reduction in dia. of solid rod,bar by successive drawing
Rod,bar or wire Drawing
Tube Drawing
- Drawn with mandrel or plug inside.
Tube Sinking
- Drawn without mandrel or plug inside.
ROD DRAWING
-Rods & tubes- not coiled drawn benches
-Draw head moved-chain drive/hydraulic mechanism
-Draw benches 300,000lb pull & 100ft of run out available
-Draw speed- 30 to 300ft/min.
Die Holder
Die Draw Head
Drawing on a draw bench
DRAWING DIE
1. Bell
2. Approach Angle
3. Bearing Region
4. Back Relief
Parts of drawing die
Bell
Approach Angle
Carbide nib
Back Relief
Bearing Region
Steel
Casing
WIRE DRAWING
- Diff. Between wire and rod - wire 5mm dia.
- Starts with coil of hot-rolled rods
- High strength material coating of Cu or Sn used as lubricant

Wire
Coil
Bull Block
Die
WIRE DRAWING
-Area reduction per drawing pass < 30-35%

-Multiple reductions required

-Wire dia. decrease after each pass - velocity & length increases

-Speed in multiple die machines 600m/min. ferrous
- 2000m/min nonferrous
-Depending on metal & reduction intermediate anneals may
be required
WIRE DRAWING
Defects :
-Seams,silvers & pipe defect from starting rod

-Center burst(or chevron cracking or cupping) occurs for low
die angles at low reduction.
Center Burst
Cold Drawing:
- Close dimensional tolerances
- Better surface finish
- Produce tube with thinner walls or smaller dia.
- Produce tubes of irregular shapes.

Types of tube drawing:
1. Sinking
2. Plug Drawing
3. Mandrel Drawing

TUBE DRAWING
Sinking fixed plug floating plug moving mandrel
TUBE DRAWING
TUBE DRAWING
Plug drawing:

-Inner/outer dia. controlled
-Greater dimensional accuracy than tube sinking
-High friction due to plug reduce reduction in area
-Floating plugs - large reduction in area & long length
of tubes drawn

Sinking :
-Internal surface become uneven
-Large Shearing at die redundant strain higher
limiting deformation lower

TUBE DRAWING
Mandrel drawing:
- Less friction between tube and mandrel
- During removal slight dia. increase & disturbs the
dimensional tolerances
DEEP DRAWING
-Drawing flat sheet into cup-shaped articles
e.g.Bath tubs,shell cases & automobiles panels

- Placing a blank over shaped die & pressing with punch
Hold Down Ring
Die
Punch
Before drawing After drawing
Die
Do
Dp
Drawability = Do(Initial blank diameter)
Dp(Diameter of the cup drawn)

DEEP DRAWING
Practical Consideration which affect drawability :
1. Die radius - 10times sheet thickness
2. Punch radius sharp radius leads to local thinning
& tearing
3. Clearance between punch & die 20-40% greater
then the sheet thickness
4. Lubricated die side reduce friction in drawing
DEEP DRAWING
Redrawing
-Reducing drawn part to small diameter & increased height
-Higher friction in redrawing leads to lesser reduction as
compared to initial draw
Types of Redrawing
1. Direct Drawing
2. Reverse or Indirect Drawing
-Better control of wrinkling obtained

PIPE/TUBE BENDING
Common method of bending:
1. Draw Bending
2. Compression Bending
3. Roll Bending
4. Stretch Bending

PIPE/TUBE BENDING
Draw Bending

Clamped work piece to a rotating form
Draw it against a pressure die
Pressure die Fixed & movable
Flow of metal - not controlled

PIPE/TUBE BENDING
Compression Bending
Work piece clamped to a fixed form & wiper shoe revolves
around the form to bend the work piece
-Flow of metal is not controlled.

Roll Bending
PIPE/TUBE BENDING
Uses three or more parallel rolls.

Three roll Bending -
-Axes of bottom rolls -fixed in a horizontal plane.
-Bending roll (top roll) used to make the bend.
Bending Roll
Driven
Rolls

Three Roll Bending
PIPE/TUBE BENDING

Four roll Bending -

PIPE/TUBE BENDING
-Two powered rolls on the left
-Two adjustable bending rolls
-Bend radius > 6 X bar dia. ( or section thk.)
Bending Roll
Driven
Rolls
Work Piece
Four Roll Bending

PIPE/TUBE BENDING
Disadvantages of Roll Bending:
1. Impractical for making more than one bend in a bar
2. Difficult to control spring back
3. Multiple passes needed
4. Slower

PIPE/TUBE BENDING
Stretch Bending :
-Used for large irregular curves
-Work piece gripped at ends & stretched around a form
-Less spring back & take one operation to do a bend
-Slow process but blocks or dies are simpler in design &
less costly
PIPE/TUBE BENDING
Die
PIPE/TUBE BENDING
Bending M/C-

1. Manual Bending
-Hand powered m/c or fixtures
-Not req. much energy

2. Press brakes
- All type of bending specially in
small lot (25-500pc)production
- Bar bent in the air

3. Mechanical Presses
-Used for mass production
-For U type bend mechanical press shown

PIPE/TUBE BENDING
4. Hydraulic Press
- Slower than mech. Press
- Exerting full force over a long stroke
- Deep bends made on hydraulic press
PIPE/TUBE BENDING
Tube Bending
-Internal support needed in tube bending
-Thick wall tube bend easily than thin-wall tube
PIPE/TUBE BENDING
1. Equipment Available
2. No. of parts required
3. Size & wall thk. of the tubing
4. The work metal
5. Bend radius
6. No. of bends in the work piece
7. Accuracy required
8. Amount of flattening tolerated
Selection of Bending Methods
PIPE/TUBE BENDING
Mandrels :
1. Rigid
-eg. Plug & Formed mandrels
2. Flexible
-eg. Laminated mandrel
3. Articulated
- eg. Round ball mandrels

Loose Fillers: Sand & low melting alloys

PIPE/TUBE BENDING
Bending tubes without mandrels :

-Tubes with thick walls - bendable than thin wall

- Bends with large radii - formable than with small radii

- Slight bends - feasible than acute bends

- Wide tolerances on permissible flattening

Thank You

Mechanical Working Processes: Vinay Bhatt

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