Shahreza Agung Alfatih

Manufacturing Process

1. Flat rolling reduces the thickness of plates and sheets. It is possible, instead,to reduce their

thickness simply by stretching the material? Would this be afeasible process? Explain. By
the student. Although stretching reduces the  thickness of materials, there are
several limitations associated with it as  compared to rolling. Stretching process is a
batch
processa n d   i t   c a n n o t   b e   c o n t i n u o u s   a s   i t   i s   i n   r o l l i n g .   T h e   r e d u c t i o
n i n   t h i c k n e s s   i s   l i m i t e d   b y necking of the sheet, depending on its strain-
hardening exponent, (see Section 2.2.4 onp. 61). Furthermore, as the sheet is stretched, the
surface finish becomes dull due to theorange-peel effect. Stretching the sheet requires
some means of clamping the material at itsends which, in turn, will leave marks on
the sheet

2. Casting is the process where metal is heated until molten. While in the molten or liquid
state it is poured into a mold or vessel to create a desired shape. Forging is the
application of thermal and mechanical energy to steel billets or ingots to cause the
material to change shape while in a solid state.

The advantages of casting include:

 No real upper size limit in casting weight

 Large range of alloy choices
 As forgings remain solid, custom alloys are far more difficult to get into production whereas with
casting, alloys including Chrome, Nickel and Moly can be added at the molten stage.
 Tooling is often less expensive than forge dies
 Smaller production “runs” required
 Complicated/complex parts are no problem

The advantages of forging include:

 Generally tougher than alternatives

 Will handle impact better than castings
 The nature of forging excludes the occurence of porosity, shrinkage, cavities and cold pour
issues.
 The tight grain structure of forgings making it mechanically strong. There is less need for
expensive alloys to attain high strength components.
 The tight grain structure offers great wear resistance without the need to make products
“superhard” We have found that, on a blank HRC 38-42 forged grinder insert wear/wash is about
the same as a high alloy HRC 46-50 cast grinder insert. The difference being a HRC 46-50 casting
does not have the ductility to handle high impact grinding.
 3. List the similarities between direct extrusion and drawing
 These are outstanding processes for producing constant cross section
• Both are commonly applied to metals
• Similar microstructure occurs for each process
• Surface roughness and lay are comparable
• Both can produce hollow parts

List the differences between direct extrusion and drawing

Extrusion is commonly done hot; drawing is done cold
• Extrusion uses larger reductions in area
• Extrusion uses a compressive pressure; drawing a tensile force
• Extrusion is done with finite lengths defined by the container capacity;
drawing can use very large lengths

4. Precision forging is defined as a flashless near net-shape forging operation which

generates high quality parts concerning surface quality and dimensional accuracy. In the
past, precision forging processes have been industrially established for axis-symmetric
parts, e.g. gearwheels and steering pinions. The main factors having an effect on the
process of forging are: tool and preform temperature, slug geometry, press settings,
process speed, lubrication and cooling, and tool shape and quality. Proper temperature
is critical for the reliable operation of the tools.

5. D

6. D

7. Near net shape forming is a cluster of technologies from forging, pressing, to rolling of

rings and rolling elements that aim at forming a component to almost the final shape.
This process enables the reduction of allowances in all operations, giving greater
performance in SKF's manufacturing channels.

8. F

9. Hot extrusion is a hot working process, which means it is done above the material’s
recrystallization temperature to keep the material from work hardening and to make it easier
to push the material through the die. Most hot extrusions are done on horizontal hydraulic
presses that range from 230 to 11,000 metric tons . Pressures range from 30 to 700 MPa ,
therefore lubrication is required, which can be oil or graphite for lower temperature
extrusions, or glass powder for higher temperature extrusions. The biggest disadvantage of
this process is its cost for machinery and its upkeep.

Cold extrusion is done at room temperature or near room temperature. The advantages of
this over hot extrusion are the lack of oxidation, higher strength due to cold working, closer
tolerances, better surface finish, and fast extrusion speeds if the material is subject to hot
shortness.
 Materials that are commonly cold extruded include: lead, tin, aluminum, copper, zirconium,
titanium, molybdenum, beryllium, vanadium, niobium, and steel.

Examples of products produced by this process are: collapsible tubes, fire extinguisher cases,
shock absorber cylinders and gear blanks.

10. Sintering - Green compacts are heated in a controlled atmosphere furnace to

temperature below the melting point, but sufficiently high to allow bonding of the
individual parts.

Green compacts are heated in a controlled atmosphere furnace to temperature below

the melting point, but sufficiently high to allow bonding of the individual parts. The nature
and strength of the bond of the particles and sintered compact depend on the complex
mechanisms of diffusion, plastic flow, and evaporation of volatile materials in compact,
recrystallization and grain growth.

Rapid heating can cause excessive thermal stresses in the part being sintered and can lead to
distortion or cracking; on the other hand, it reduces cycle times.

Slow heating has the advantage of allowing heating and diffusion to occur more uniformly.

11. By the student. The additional cost can easily be justified because of the numerous advantages
inherent in P/M production (see also p. 508). For example, P/M parts can be produced at net or
near-net shapes, thus reducing or eliminating finishing operations. Powder metallurgy allows
the production of relatively complex shapes from exotic alloys which would otherwise be
difficult to manufacture by other means. Also, the self-lubricating capability of sintered metal
powders makes P/M parts attractive for bushings, gears, races, and cams; the ability to make
alloys with compositions that cannot be cast is attractive for particular applications, especially in
the electronics industry. Compaction of powders has certain advantages over other forming
operations, such as forging, because by controlling porosity (hence their density) makes them
advantageous in applications where weight is critical. (See Chapter 40 for various cost
considerations.)

12. Additive manufacturing, or 3D printing, has been a popular method of creating

prototypes since the 1980s and is quickly becoming the fastest, most affordable
way to create custom consumer goods, as well. But how does this trendy
technology work?
There are several different methods of 3D printing, but the most widely used is a
process known as Fused Deposition Modeling (FDM). FDM printers use a
thermoplastic filament, which is heated to its melting point and then extruded,
layer by layer, to create a three dimensional object.
The technology behind FDM was invented in the 1980s by Scott Crump, co-
founder and chairman of Stratasys Ltd., a leading manufacturer of 3D printers.
Other 3D printing organizations have since adopted similar technologies under
different names. The Brooklyn-based company MakerBot (now owned by
Stratasys), was founded on a nearly identical technology known as Fused
Filament Fabrication (FFF).