02-Oct-14

Lesson Objectives:
Todays lesson objectives:
Shape rolling and other rolling
processes
Introduction to forging processes for
metals
Introduction to forging operations

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Rolling of Metals

Shape-rolling Operations
In addition to flat rolling, various

shapes can be produced by shape

rolling.
Straight and long structural shapes,
such as solid bars (with various crosssections), channels, I-beams, railroad
rails are rolled by passing the stock
through a set of specially designed rolls.
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Shape Rolling
Stages in the shape
rolling of an Hsection part.
Various other
structural sections,
such as channels
and I-beams, are
also rolled by this
kind of process.

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Ring Rolling
A thick ring is expanded into a large

diameter ring with a reduced cross-section.

The ring is placed between two rolls closer
together, one of which is driven and its
thickness is reduced by bringing the rolls
closer together as they rotate.
Applications: ball and roller bearing races,
steel tires for railroad wheels, and rings for
pipes, pressure vessels, and rotating
machinery .
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Ring Rolling (cont.)

Advantages: material savings, ideal grain

orientation, strengthening through cold

working

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Ring rolling used to reduce the wall thickness and

increase the diameter of a ring:
(1) start, and (2) completion of process

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Ring-Rolling

(a) Schematic illustration of

a ring-rolling operation.
Thickness reduction results
in an increase in the part
diameter. (b) Examples of
cross-sections that can be
formed by ring rolling.

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Thread Rolling
It is a process in a cold-forming process by

which straight or tapered threads are formed on

round rods, by passing them between dies.
Advantages over thread cutting (machining):

Higher production rates

Better material utilization
Stronger threads due to work hardening
Better fatigue resistance due to compressive stresses
introduced by rolling

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Thread-Rolling
Thread-rolling
processes: (a) and
(c) reciprocating
flat dies; (b) tworoller dies.
Threaded fasteners,
such as bolts, are
made economically
by these processes,
at high rates of
production.

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Thread-Rolling

(a) Features of a machined or rolled thread. (b) Grain flow in

machined and rolled threads. Unlike machining, which cuts
through the grains of the metal, the rolling of threads causes
improved strength, because of cold working and favorable grain
flow.
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Defects in Flat Rolling

Few defects occurred in flat rolling

process may not only degrade surface

appearance but may adversely affect
the strength, formability and etc.
Examples of defects in flat rolling are:

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Defects in Flat Rolling

Wavy edges the strip is

thinner along its edges that
its centre, thus the edges
elongate more than centre.

Cracks result of poor

material ductility at the
rolling temperature

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Defects in Flat Rolling

Edge cracks poor

quality of materials
at the edges

Alligatoring complex
phenomenon caused by
nonuniform bulk deformation
process or presence of defects
in the original materials
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Forging of Metals

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Forging
It is a process in which the workpiece is

shaped by compressive forces applied

through various dies and tools.
Oldest metalworking operation
Simple forging operations can be
performed with a heavy hand hammer,
traditionally done by blacksmiths.

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Forging
Most forgings, require a set of dies and

a press or a forging hammer.

Forging operations produce discrete
parts.
Typical forged products are bolts and
rivets, connecting rods, shafts for
turbines, gears, hand tools, aircraft
components, etc.
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Forging
(a)

(b)

Figure 14.1 (a) Schematic illustration of the steps

involved in forging a bevel gear with a shaft. Source:
Forging Industry Association. (b) Landing-gear
components for the C5A and C5B transport aircraft,
made by forging. Source: Wyman-Gordon Company.
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Characteristics of Forging
Processes
TABLE 14.1
Process
Open die

Closed die

Blocker type
Conventional type

Precision type

Advantages
Simple, inexpensive dies; useful for small
quantities; wide range of sizes available;
good strength characteristics
Relatively good utilization of material;
generally better properties than open-die
forgings; good dimensional accuracy; high
production rates; good reproducibility
Low die costs; high production rates
Requires much less machining than blocker
type; high production rates; good utilization
of material
Close tolerances; machining often
unnecessary; very good material utilization;
very thin webs and flanges possible

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Limitations
Limited to simple shapes; difficult to hold close
tolerances; machining to final shape necessary;
low production rate; relatively poor utilization of
material; high degree of skill required
High die cost for small quantities; machining
often necessary

Machining to final shape necessary; thick webs

and large fillets necessary
Somewhat higher die cost than blocker type

Requires high forces, intricate dies, and provision

for removing forging from dies

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Classification of Forging
Operations
Cold vs. hot forging:
Hot or warm forging most common, due to
the significant deformation and the need to
reduce strength and increase ductility of work
metal
Cold forging - advantage is increased strength
that results from strain hardening

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Classification of Forging
Operations (cont.)
Impact vs. press forging:
Forge hammer - applies an impact load
Forge press - applies gradual pressure

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Any questions??

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