metal forming operations rolling: makes sheet metal (hot or cold) forging: makes strong solid parts...
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Metal Forming Operations
Rolling: makes sheet metal(hot or cold)
Forging: makes strong solid parts(hot or cold)
Kalpakjian
Kalpakjian
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Wire drawing: Makes strong small dia. wire(hot or cold)
Extrusion:makes complex cross-sections from soft metals and plastics(hot)
Kalpakjian
Kalpakjian
www.capalex.com
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Bending: (2D)Bend sheet metal about single axis(hot or cold)
Deep drawing (3D)Makes “cups” from sheet metal,for mass production.(cold)
Kalpakjian
Kalpakjian
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Spinning:Makes “cups” from sheet metal,for lower production.(cold)
Roll forming (Hot):Moves bulk metal, makes I-beams
Kalpakjian
Kalpakjian
Kalpakjian
Roll forming (Cold):Bends sheetmetal into complex cross-sections
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Shearing:Cut or punch sheetmetal(hot or cold)
Kalpakjian
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ASM Metals Handbook Vol.9
Bralla
FormingOriented flowlines decrease fracture risk from grain boundaries, improve strength along flow direction.(Directional properties).Especially seen in:-Forging-Rolling-Drawing
Cracks tend to start where grain boundaries intersect surface. Forging minimizes these.
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Thread-rolling for bolts: Rolled threads stronger than machined (and less expensive)
Kalpakjian
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Directional Properties in RollingOriented flowlines:-Less ductility when bent in one direction-More ductility when bent in the other
Kalpakjian
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Slab Production: Hot Rolling
www.labware.com
www.falckacciai.it www.beautifuliron.com
Color & Temp
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Progressive Hot Rolling: smaller, uniform grains
Kalpakjian
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Hot Working:Forging
Paul Berenson, www.paulb.comT.Green, WIT
www.smeedwerkunica.nl
Open Die Forging
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Hydraulic press Mechanical press with an eccentric drive: fasterSlow but high forceand low cost
Forging Presses
Kalpakjian Erie Press
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Forging Presses
Knuckle-joint press Screw press Gravity drop hammer:Simplest
Kalpakjian
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Forging: Closed Die Forging
Kalpakjian
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Forging: Heat LossMetal near die surfaces are coolest, flow less
www.lft.uni-
erlangen.de www.freedomalloysusa.com
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Kalpakjian
Upset Forging (hot or cold)Bolt manufacture
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Roll Forming (hot):
I-beams
Kalpakjian
Lunchtime on a Crossbeam, Unknown, www.buffalogames.com www.civil.ubc.ca
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Extrusion (hot or cold):Typ.: Alum., soft metals
With special lubes: steels
~Any cross-section
Inexpensive dies
Good finish
T.Green, WIT en.wikipedia.org
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Extrusion:
Hollow cross-sections: Use Mandrels
Kalpakjianwww.abra.net.au
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Mannesmann Process: Piercing (Hot) Seamless pipe, tube
Kalpakjian
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Cold-Working (vs. Hot):Products:• Better tolerances• Much better surface finish• Elongated (and smaller) grains• Turns inexpensive alloys into stronger but less ductile products• Sheetmetal lends itself to cold working, not hot working
Processes:• Higher processing forces• Larger and stronger machinery• Less ductility available• Lower energy use
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Cold Rolling: Sheetmetal production
Kalpakjian
www.nzsteel.co.nz finance.pipex.com
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Cold Rolling: Sheetmetal production
Cluster rolls support smaller contacting rolls
www.sendzimir.com
www.elgiloy.com
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Cold Rolling: Sheetmetal production
Residual Stresses may lead to warping after bar is machined
Large reduction Small reduction
Kalpakjian
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Roll Forming of Sheetmetal (cold)
Kalpakjian
www.cometroll.com www.safeair-dowco.com
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Roll Forming of sheetmetal
www.mortonbuildings.com
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Punching & Blanking of Sheetmetal
Punching (Scrap)
Blanking (Saved: a “blank”)
Punch
Die
Stripper plate
T.Green, WIT
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Punching ofSheetmetal
Kalpakjian
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Blanking of Sheetmetal: Efficient Nesting of Blanks
Kalpakjian
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Sheetmetal: Bending
Kalpakjian
Springback:
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Sheetmetal: Minimum Bend Radius
Kalpakjian
Tight radius bends (folds) require metal with ~40% ductility
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Kalpakjian
Bending of SheetmetalUse notches to avoid tearing and wrinkling in right-angle bends
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Press Brakes:For lower production
volumes
10-30 foot long
50-3000 tons
Bending of Sheetmetal
www.loomismetals.com
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Bending:Press-Brake Operations
Kalpakjian
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For large quantities, forging and die casting are more economical. Sand casting is the more economical process for fewer than about 20,000 pieces.
Relative Unit Costs of a Small Connecting Rod
Kalpakjian
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Deep Drawing (cold, for sheetmetal)- Punch draws blank into die- Metal is supported on both sides to avoid wrinkling- Hold-down pressure (blankholder force) is primary process variable if too high: tearing if too low: wrinkling
Kalpakjian
www.endo-mfg.co.jp
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Deep Drawing“Draw beads” may be used to control metal flow
Kalpakjian
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www.dissco.co.nz
SpinningIdeal for • Lower production volumes• Large parts• Inexpensive tooling
www.traditional-building.com
www.ashfordmetalspinning.co.uk
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Spinning videos
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Cost comparison: manufacturing a round sheet-metal container by spinning and deep drawing. For small quantities, spinning is more economical.
Kalpakjian
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Finite Element SimulationsPredict and minimize tearing and wrinkling locations
nsmwww.eng.ohio-state.edu
www.esi-group.com
tmku209.ctw.utwente.nl
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Progressive Stamping DiesCommon method to handle complex parts
www.nissin-precision.com
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Tube-drawingDOM: Drawn Over Mandrel Tubing
Seamless
Thin wall, tight tolerance, strong
Kalpakjian
www.twmetals.com
Malicky
“Floating plug”
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Bicycles: Butted DOM tubingIncreased wall thickness at ends
Reinforces high stress points
materials.npl.co.uk
www.torelli.com
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Diego Rivera, Detroit Industry, Detroit Institute of Art
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References
Kalpakjian: http://www.nd.edu/~manufact/index3.htm
Bralla: James G. Bralla, Design for Manufacturing Handbook, McGraw-Hill, 2nd Edition. In: www.rose-hulman.edu/~stienstr