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FORGING
Forging can be defined as the method of shaping the heated metal by compression or by applying the force in the presence of pressure.
1) Open die
Open die forging is the hot forging process in which metal is shaped by hammering or pressing between flat or simple contour dies.
2) Impression die
Two or more dies containing impressions of the part shape are brought together, the work piece undergoes plastic deformation until its enlarged sides touches the die side walls.
3) Closed die
In this process a billet with carefully controlled volume is deformed by a punch in order to fill a die cavity without any loss of material. In this process no flash is formed.
DEFECTS OF FORGING
Dirt, slag, blow holes arises due to melting practices. Cracks, scales or bad surface and segregations arises. Due to improper heating of the forging decarburization takes place. Due to improper alignment between top and bottom dies mismatch takes place.
ADVANTAGES OF FORGING
Variety of sizes i.e. forged part weighing from single pound to 400,000 pound. Variety of shapes. Material saving as it reduce material cost. Structural strength as it provides a degree of structural integrity that is unmatched by other metalworking processes.
APPLICATIONS OF FORGING
Typical forged part are crankshafts and connecting rods for engines, turbine disk, gears, wheels, bolt head, hand tools and many type of structural components for machinery and transportation equipment.
INDEX
ROLLING ROLLING MILL DEFECTS IN ROLLING
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Rolling is a bulk deformation process in which the thickness of the work is reduced by compressive forces exerted by two opposing rolls. The rolls rotate to pull and simultaneously squeeze the work
Rolling
between them.
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Rolling
As any other metal forming process, rolling can be performed hot (hot rolling) or cold (cold rolling). Most rolling is carried out by hot rolling, owing to the large amount of deformation required. Hot-rolled metal is generally free of residual stresses, and has isotropic properties. On the other hand, it does not have close dimentional tolerances, and the surface has a characteristic oxide scale. Moreover, cold rolled metals are stronger.
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Rolling
This figure shows the contact length between the work and the rolls, the initial and final work velocities, in addition to the velocity of the rolls:
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Rolling Mill
A rolling mill consists of one or more roll stands, motor drive, reduction gears, flywheel and coupling gears between units The roll stand is the main part of the mill, where the rolling process is performed The body of the roll may be either flat for rolling sheets (plates or strips) or grooved for making structural members (channel, I-beam, rail)
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Continue
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Rolling mills are classified according to the number and arrangement of rolls in a stand. They are classified as : (A) For hot rolling of metals (1) Two high rolling mill (2) Three-high rolling mill (B) For cold rolling of metals (1) Four high rolling mill (2) Cluster rolling mill.
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Rolling mills
Various roll arrangements used in rolling mills :-
Cluster
tandem
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Defects in rolling
There may be defects on the surfaces of the rolled plates and sheets. The various defects are: Surface defects Structural defects Wavy edges Zipper cracks Edge cracks Alligatoring
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Rolling Defects
Structural defects in sheet rolling:
Wavy Edges
Center cracking
Edge cracking
Alligatoring
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EXTRUSION
Extrusion It is a process where a billet is forced through a die. Extrusion produces only compressive and shear forces Parts have constant cross-section Typical Products of Extrusion Sliding Doors, tubing having various cross-sections, structural and architectural shapes and door and window frames.
Direct Extrusion
Types of Extrusion
Hot Extrusion
It is done at fairly high temperatures, approximately 50 to 75% of the melting point of the metal for metals and alloys that do not have sufficient ductility at room temperature, or in order to reduce the forces required.
Cold Extrusion
It is the process done at room temperature or sligthly elevated temperatures. Combination of operations, such as direct and indirect extrusion and forging. Advantages : Improved mechanical properties No oxidation takes place Improved surface finish
Fig : Two examples of cold extrusion. Thin arrows indicate the direction of metal flow during extrusion.
Impact Extrusion
Similar to indirect extrusion Punch descends rapidly on the blank, which is extruded backward
Fig : Schematic illustration of the impact-extrusion process. The extruded parts are stripped by the use of a stripper plate, because they tend to stick to the punch.
Hydrostatic Extrusion
The pressure required for extrusion is supplied through and incompressible fluid medium surrounding the billet Usually carried at room temperature, typically using vegetable oils as the fluid Brittle materials are extruded generally by this method It increases ductility of the material It has complex nature of the tooling
Extrusion Defects
1. 2. 3. Surface cracking. Extrusion defect. Internal Cracking
ADVANTAGES
The tooling cost is low Hardness and the yield strength of the material are increased. In most applications, no further machining is necessary.
LIMITATIONS
The process is limited to ductile materials. Extruded products might suffer from surface cracking Internal cracking might also occur.
THE END