WORKSHOP PRACTICE

(THEORY) :ESC-104
LECTURE-6
Presented By:
Jagdip Chauhan
Assistant Professor
Mechanical Engineering Department
Guru Jambheswar University of Science & Technology, Hisar
Metal forming processes:
Metal forming: A large set of manufacturing processes in which the
material is deformed plastically to take the shape of the die
geometry. The tools used for such deformation are called a die,
punch, etc. depending on the type of process.
Plastic deformation: Stresses beyond the yield strength of the
workpiece material are required.
BLANKING:
• Blanking is a cutting process in which a piece of sheet metal is
removed from a larger piece of stock by applying a great enough
shearing force. In this process, the piece removed, called the blank,
does not scrap but rather the desired part. Blanking can be used to cut
out parts in almost any 2D shape but is most commonly used to cut
workpieces with simple geometries that will be further shaped in
subsequent processes. Often multiple sheets are blanked in a single
operation. Final parts that are produced using blanking include gears,
jewelry, and watch or clock components. Blanked parts typically
require secondary finishing to smooth out burrs along the bottom
edge.
PUNCHING:

• Punching is a cutting process in which material is

removed from a piece of sheet metal by applying a
great enough shearing force. Punching is very
similar to blanking except that the removed
material, called the slug, is scrap and leaves behind
the desired internal feature in the sheet, such as a
hole or slot. Punching can be used to produce holes
and cutouts of various shapes and sizes. The most
common punched holes are simple geometric shapes
(circle, square, rectangle, etc.)
 PUNCHING CHARACTERISTICS:

• The characteristics of punching are:

• It is the most cost-effective process of making holes in the strip or sheet
metal for average to high fabrication.
• It can create multiple shaped holes.
• Punches and dies are usually fabricated from conventional tool steel or
carbides
• It is a quick process.
 PIERCING:
Piercing - The typical punching operation, in which a cylindrical punch
pierces a hole into the sheet.
FORGING:
• It is a deformation process in which the workpiece is compressed between two dies, using
either impact load or hydraulic load (or gradual load) to deform it.
• It is used to make a variety of high-strength components for automotive, aerospace, and
other applications. The components include engine crankshafts, connecting rods, gears,
aircraft structural components, jet engine turbine parts, etc.
Category based on temperature: cold, warm, hot forging
• Category based on presses: impact load => forging hammer; gradual pressure => forging
press
• Category based on the type of forming: Open die forging, impression die forging, flashless
forging.
In open die forging, the workpiece is compressed between two flat platens or dies, thus
allowing the metal to flow without any restriction in the sideward direction relative to the die
surfaces.

Open Die Forging

FORGING:

In impression die forging, the die surfaces In flashless forging, the workpiece
contain a shape that is given to the is fully restricted within the die
workpiece during compression, thus and no flash is produced. The
restricting the metal flow significantly. amount of initial workpiece used
There is some extra deformed material must be controlled accurately so
outside the die impression which is called that it matches the volume of the
flash. This will be trimmed off later. die cavity.
ROLLING :
Rolling is a metal forming process in which the thickness of the work
is reduced by compressive forces exerted by two or multiple rollers
rotating in opposite directions. Flat rolling is shown in the figure.
Similarly, shape rolling is also possible like a square cross-section
formed into a shape such as an I-beam or L-beam.
ROLLING :
Important terminologies:
Bloom: It has a square cross-section of 150 mm x 150 mm or more. Blooms are
rolled into structural shapes like rails for railroad tracks.
Slab: It is rolled from an ingot or a bloom and has a rectangular cross-section of
250 mm in width or more and a thickness of 40 mm or more. Slabs are rolled
into plates, sheets, and strips. Hot-rolled plates are generally used in
shipbuilding, bridges, boilers, welded structures for various heavy machines,
and many other products.
Billet: It is rolled from bloom and is square in cross-section with dimensions
40mm on a side or more. Billets are rolled into bars and rods. They become raw
materials for machining, Wire drawing, forging, extrusion, etc.
ROLLING :
TYPE OF ROLLING:
Rolling is classified according to the temperature of the workpiece rolled. If the temperature
of the metal is above its recrystallization temperature, then the process is termed hot rolling
otherwise cold rolling.

Hot Rolling: hot working processes, large deformation can be successively repeated, as the
metal remains soft and ductile. The metal stock is subjected to high compressive stresses as a
result of the friction between the rolls and the metal surface.

Cold Rolling: The rolling process is done below the recrystallization temperature of the metal
& it varies upon the metal, room temperature can also be below the recrystallization
temperature. In this process, the force is much more required than the hot working process to
pass the metal from the rollers and this process offers a good surface finish.
ROLLING MILLS:
Two high rolling mills: This type of rolling mill consists of two rolls rotating in
opposite directions.
Roll diameters: 0.6 to 1.4 m
Types: reversing or non-reversing.
Non-reversing mill: rolls rotate only in one direction, and the slab always moves
from entry to exit side.
Reversing mill: direction of roll rotation is reversed, after each pass, so that the
slab can be passed through in both directions. This permits continuous
reductions to be made through the same pairs of rolls.
ROLLING MILLS:
Three high rolling mills: In this case, there are three rolls one above the
other. At a time, for single-pass, two rolls will be used. The roll direction
will not be changed in this case. The top two rolls will be used for the
first reduction and the sheet is shifted to the bottom two rolls and further
reduction is done. This cycle is continued till actual reduction is attained.
Disadvantage: the automated mechanism is required to shift the slab.

Four high rolling mills: This consists of two small rolls for thickness
reduction and two large backing rolls to support the small rolls. The
small rolls will reduce the roll force required as the roll-sheet contact
area will be reduced. The large backing rolls are required to reduce the
elastic deflection of small rolls when the sheet passes between them.
ROLLING MILLS:
Cluster rolling mill: This uses smaller rolls for rolling.

Tandem rolling mill:

This consists of a series of rolling stations of the order of 8 to 10. In each station, thickness
reduction is given to the sheet. With each rolling station, the work velocity increases. This is
used in industry practice, along with continuous casting operation. This results in a reduction
in floor space, and shorter manufacturing lead time.
ROLLING MILLS:
Thread rolling is used to create threads on
cylindrical parts by rolling them between two dies
as shown in the figure. It is used for the mass
production of externally threaded parts like bolts
and screws.
Ring rolling is a forming process in which a thick-
walled ring part of a smaller diameter is rolled into
a thin-walled ring of a larger diameter. As the
thick-walled ring is compressed, the deformed
material elongates, making the diameter of the
ring to be enlarged. Application: ball and roller
bearing races, steel tires for railroad wheels, rings
for pipes, pressure vessels, and rotating
machinery.
EXTRUSION:
Extrusion is a bulk-forming process in which the work metal is forced or
compressed to flow through a die hole to produce a desired cross-sectional
shape. Example: squeezing toothpaste from a toothpaste tube.

Advantages :
- Variety of shapes is possible, especially using hot extrusion
- Grain structure and strength properties are enhanced in cold and warm
extrusion
- Close tolerances are possible, mainly in cold extrusion

Types of extrusion: Direct or forward extrusion, Indirect or backward extrusion

EXTRUSION:
Direct extrusion: - A metal billet is first loaded into a container having die holes.
A ram compresses the material, forcing it to flow through the die holes. - Some
extra portion of the billet will be present at the end of the process that cannot be
extruded and is called the butt. It is separated from the product by cutting it just
beyond the exit of the die
 EXTRUSION:
Indirect extrusion: - In this type, the die is mounted to the ram and not on the container. As
the ram compresses the metal, it flows through the die hole on the ram side which is in
opposite direction to the movement of the ram.

Since there is no relative motion between the billet and the container, there is no friction at
the interface, and hence the ram force is lower than indirect extrusion.

Limitations: lower rigidity of the hollow ram, and difficulty in supporting the extruded
product at the exit.
 Q&A

I am done
Thank You