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Week 5
Week 5
(MSE – 881)
➢ The tool, usually called a die, applies stresses that exceed the yield strength of
the metal
✓ High ductility
➢ Other factors:
✓ Strain rate
Basic Types of Deformation Processes
▪ Rolling ▪ Bending
▪ Extrusion ▪ Cutting
✓ In forging, a workpiece is compressed between two opposing dies, so that the die
shapes are imparted to the work.
Forging
➢ Also, basic metals industries use forging to establish basic form of large parts
✓ Hot or warm forging – most common, due to the significant deformation and
the need to reduce strength and increase ductility of work metal
✓ Friction between work and die surfaces constrains lateral flow of work,
transfer at and near die surfaces, which cools the metal and increases its
resistance to deformation
Open-Die Forging with No Friction
Open-Die Forging with No Friction
Open-Die Forging: Examples
https://www.youtube.com/watch?v=XTU0Z-FkhtU
Impression-Die Forging
Impression-Die Forging
https://www.youtube.com/watch?v=-w7E88zox6w https://www.youtube.com/watch?v=YobXFODkp50
Impression-Die Forging
Impression-Die Forging
Impression-Die Forging
Impression-Die Forging
▪ Advantages of impression-die forging compared to machining
from solid stock:
▪ Greater strength
▪ Limitations:
Figure 19.17 Flashless forging: (1) just before initial contact with
workpiece, (2) partial compression, and (3) final punch and die
closure.
Flashless Forging
Flashless Forging
Hot rolled steel is steel that has been roll-pressed Typically harder and stronger than standard hot
at very high temperatures rolled steels.
A scaled surface—a remnant of cooling from Better, more finished surfaces with closer
extreme temperatures tolerances
Less precise finishing
Often have well-defined edges and corners
> Used for strip & sheets making
Rolled Products Made of Steel
Disadvantage:
Figure 19.5 Various configurations of rolling mills: (a) 2-high rolling mill.
Three-High Rolling Mill
Figure 19.5 Various configurations of rolling mills: (b) 3-high rolling mill.
Four-High Rolling Mill
Figure 19.5 Various configurations of rolling mills: (c) four-high rolling mill
Cluster Rolling Mill
Figure 19.6 Thread rolling with flat dies: (1) start of cycle, and (2) end of cycle.
Ring Rolling
Ring Rolling
✓ Applications: ball and roller bearing races, steel tires for railroad wheels, and rings for
pipes, pressure vessels, and rotating machinery
✓ Advantages: material savings, ideal grain orientation, strengthening through cold working
Structure Modification