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Metal Forming
Large group of manufacturing processes in which plastic deformation is used to change the shape of metal workpieces The tool, usually called a die, applies stresses that exceed yield strength of metal The metal takes a shape determined by the geometry of the die
where K = strength coefficient; and n = strain hardening exponent Stress and strain in flow curve are true stress and true strain
Flow Stress
For most metals at room temperature, strength increases when deformed due to strain hardening Flow stress = instantaneous value of stress required to continue deforming the material
Yf K n
where Yf = flow stress, that is, the yield strength as a function of strain
Warm working is metal forming at temperatures above the room temperature but bellow the
recrystallization one. Advantages: lower forces and power, more complex part shapes, no annealing is required. Disadvantages: some investment in furnaces is needed.
Definitions
Plastic Deformation Processes
Operations that induce shape changes on the work piece by plastic deformation under forces applied by various tools and dies.
Sheet-Forming Processes
In sheet metalworking operations, the cross-section of work piece does not changethe material is only subjected to shape changes. The ratio cross-section area/volume is very high. Sheet metalworking operations are performed on thin (less than 6 mm) sheets, strips or coils of metal by means of a set of tools called punch and die on machine tools called stamping presses. They are always performed as cold working operations.
Forging: The workpiece is compressed between two opposing dies so that the die
shapes are imparted to the work.
Extrusion: The work material is forced to flow through a die opening taking its
shape
Rolling
Definition Rolling is a Bulk Deformation Process in which the thickness of the work is reduced by compressive forces exerted by two opposing rolls
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Rolling
Rolling
Important Applications: Steel Plants, Raw stock production (sheets, tubes, Rods, etc.) Screw manufacture
Rolling Basics
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stationary die
Screw manufacture:
rolling die thread rolling machine
Forging
Definition
Forging is a Bulk Deformation Process in which the work is compressed between two dies. According to the degree to which the flow of the metal is constrained by the dies there are three types of forging:
Forging
[source:www.scotforge.com]
A material is pushed or drawn through a die of the desired crosssection .Any solid or hollow cross-section may be produced by extrusion, which can create essentially semi-finished parts. The metal can forcing through a die in the same direction or opposite direction.
Extrusion
Typical use: ductile metals (Cu, Steel, Al, Mg), Plastics, Rubbers Common products: Al frames of white-boards, doors, windows,
chamber
hydraulic piston
stock
chamber
The cross-sections that can be produced vary from solid round, rectangular, to L shapes, T shapes. Extrusion may be continuous (theoretically producing indefinitely long material) or semi-continuous (producing many pieces). Extrusions can be done with the material hot or cold.
Extruded products Typical products made by extrusion are railings for sliding doors, tubing having carious cross-sections, structural and architectural shapes, and door and windows frames.
Extruded products
Direct extrusion: A metal billet is located into a container, and a ram compresses the material, forcing it to flow through one or more openings in a die at the opposite end of the container. Indirect extrusion: The die is mounted to the ram rather than at the opposite end of the container. One advantage of the indirect extrusion process is that there is no friction, during the process, between the billet and the container liner
Drawing
stock (bar)
wire
F (pulling force)
WHAT is DRAWING?
Drawing is an operation in which the cross-section of solid rod, wire or tubing is reduced or changed in shape by pulling it through a die.
The principle of this procedure consist of reducing the thickness of a pointed ,tapered wire by drawing it through a conical opening in a tool made of a hard material.The wire will take shape of the hole.
Drawing improves strength and hardness when these properties are to be developed by cold work and not by subsequent heat treatment
Where is it used? This process is widely used for the production of thicker walled seamless tubes and cylinders therefore; shafts, spindles, and small pistons and as the raw material for fasteners such as rivets, bolts, screws.
DRAWING TOOLS
The most important tool in the drawing process is without doubt the drawplate.This consist of a plate of high grade steel into which similar shaped holes have been placed whose size in evenly reduced from one hole to another. The most common drawplate have round holes and are used to reduce the size of round wire.
drawbench