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CONTENTS
Metal working,
Elastic and plastic deformation
Concept of strain hardening
Hot and cold working
Rolling: Principle and operations, Roll pass sequence
Forging, Forging operations, Forging: Method of
forging, Forging hammers and presses
Extrusion
Wire and tube drawing processes.
Principle of forging tool design
Cold working processes: Shearing, Drawing Squeezing,
Blanking, Piercing, deep drawing, Coining and
embossing
Metal working defects
Cold heading and Riveting.
Metal Working
Metalworking
is
the
process
of working with metals to create individual
parts, assemblies, or large-scale structures.
The term covers a wide range of work from
large ships and bridges to precise engine parts
and delicate jewelry.
It therefore includes a correspondingly wide
range of skills, processes, and tools.
Cold Working
Plastic deformation of metals below the
recrystallization temperature is known as cold working.
It is generally performed at room temperature.
In some cases, slightly elevated temperatures may be
used to provide increased ductility and reduced
strength.
Cold working offers a number of distinct advantages,
and for this reason various cold-working processes
have become extremely important.
Significant advances in recent years have extended the
use of cold forming, and the trend appears likely to
continue.
Disadvantages of cold-working
1. Higher forces are required for deformation.
2. Heavier and more powerful equipment is
required.
3. Less ductility is available.
4. Metal surfaces must be clean and scale-free.
5. Strain hardening occurs ( may require
intermediate annealing ).
6. Undesirable residual stresses may be produced
Hot Working
Rolling
Rolling is a metal forming process in which the
thickness of the work is reduced by
compressive forces exerted by two rolls
rotating in opposite direction.
Flat rolling is shown in figure. Similarly shape
rolling is also possible like a square cross
section is formed into a shape such as an Ibeam, L-beam.
Rolling:
Important terminologies
Bloom: It has a square cross section 150 mm x
150 mm or more.
Slab: It is rolled from an ingot or a bloom and
has a rectangular cross section of 250 mm
width or more and thickness 40 mm or more.
Billet: It is rolled from a bloom and is square in
cross-section with dimensions 40mm on a side
or more.
Coining Vs Embossing
DRAWING
Drawing is a metal forming process involving
pulling a work piece (cold or hot) through a
die providing reduction of the cross section of
the work piece
DRAWING
Drawing is the process most commonly used to
make wires from round bars; this process is very
similar to extrusion, except that instead of
pressure from the back end, in drawing, the wire
is pulled from the side where it emerges from
the circular die.
Dies are made of specially hardened tool steels,
or tungsten carbide. Diamond dies are used for
drawing very fine wires. Drawing may be hot
(the stock is heated to a high temperature for
processing), or cold (the stock is not heated).
RIVETING