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SHARDA UNIVERSITY

FORGING ROLLING EXTRUSION

SUBMITTED BYANIMESH JAISWAL MD.MANJAR HUSSAIN KUNAL KAPUR

SUBMITTED TOMANISH KUMAR YADAV

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.

TYPES OF FORGING PROCESSES


Open die forging Impression die forging Closed die forging

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.

The rolling process (specifically: flat rolling)

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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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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 :-

Two-high Three-high Four-high

Cluster

tandem

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(1) Two high rolling mill


It is basically of two types i.e. non-reversing and reversing rolling mill. The two high non-reversing rolling stand arrangement is the most common arrangement. In this the rolls always move in only one direction, while in a two-high reversing rolling stand the direction of roll rotation can be reversed. This type is used in blooming and slabbing 21

(2) Three-high rolling mill


It is used for rolling of two continuous passes in a rolling sequence without reversing the drives. The metal has passed through the bottom roll set, the end of the metal is entered into the other set of the rolls for the next pass. A table-tilting arrangement is required to bring the metal to the level with the rolls Such types of arrangement is used for making 22 plates and sections.

(3) Four high rolling mill


It is generally a two-high rolling mill, but with small sized rolls. The other two rolls are the backup rolls for providing the necessary rigidity to the small rolls. It is used for both hot and cold rolling of wideplates and sheets.

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(4) Cluster rolling mill


It uses backup rolls to support the smaller work rolls. The roll in contact with the work can be as small as 1by4 inc. in diameter. Foil is always rolled on cluster mills since the small thickness requires small-diameter rolls.

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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.

The Extrusion Process


Types of Extrusion : Direct Extrusion (or) Forward Extrusion Billet is placed in a
chamber and forced through a die opening by a hydraulically-driven ram or pressing stem.

Indirect Extrusion Die moves towards the billet.

Hydrostatic Extrusion The billet is smaller in diameter that the


chamber, which is filled with a fluid, and the pressure is transmitted to the billet by a ram.

Direct Extrusion

Fig : Schematic illustration of direct extrusion process.

Types of Extrusion

Fig : Types of Extrusion (a) indirect (b) hydrostatic (c) lateral

Types of Metal flow in extruding with square dies.

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

Fig : General view of a 9MN (1000-ton) hydraulicextrusion press.

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

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