06:19 26/03/2024 Thẻ ghi nhớ: Manufacturing Processes Quiz Bulk Deformation | Quizlet

Manufacturing Processes Quiz Bulk Deformation

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Metal forming operations which cause significant shape change by deforming metal
Bulk Deformation
parts whose initial form is bulk rather than sheet

Hotworking significant shape change can be accomplished

Coldworking strength is increased during shape change

Rolling - slab or plate is squeezed between

4 Basic Bulk Deformation Processes
opposing rolls
2. Forging - work is squeezed and shaped between opposing dies
3. Extrusion - work is squeezed through a die opening, thereby taking the shape of the
opening
4. Wire and bar drawing - diameter of wire or bar is reduced by pulling it through a die
opening

Deformation process in which work thickness is

reduced by compressive forces exerted by two
opposing rolls (shown below is flat rolling)
Rotating rolls perform two main functions:
Rolling
Pull the work into the gap between them by
friction between workpart and rolls
Simultaneously squeeze the work to reduce its
cross section

Flat Rolling used to reduce thickness of a rectangular cross section

Shape Rolling square cross section is formed into a shape such as an I-beam

Hot rolling can achieve significant deformation

Cold Rolling low temperature deformation of sheets and simple shapes

bulk deformation process used to form threads on cylindrical parts by rolling them
between two dies
-cold rolling
-mass production of screws and bolts
Thread Rolling
Advantages over thread cutting (machining):
Higher production rates
Better material utilization
Stronger threads and better fatigue resistance

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deformation process in which a thick walled ring of smaller diameter is rolled into a thin
walled ring of larger diameter
-As thick-walled ring is compressed, deformed metal elongates, causing diameter to
Ring Rolling
enlarge
Products: ball and roller bearing races, steel tires for railroad wheels, pressure vessels,
and rotating machinery

Deformation process in which work is compressed

between two dies
Oldest of the metal forming operations
Products: engine crankshafts, connecting rods,
Forging
gears, jet engine turbine parts
Also, basic metals industries use forging to
establish shape of large parts that are then
machined to final geometry and size

Hot Forging advantage: reduction in strength and increase in ductility of work metal

Cold Forging advantage: increased strength due to strain hardening

Impact Forging Forge hammer - applies an impact force

Press Forging Forge press - applies gradual force

Work is compressed between two flat dies, allowing

metal to flow laterally with minimum constraint
Open die forging

- Workpiece acquires the shape of the die cavities

(impressions) while being forged between two
shaped dies
impression die forging
- It is usually carried out at elevated temperatures
- Some of the material flows outward and forms a
flash

Flashless Forging

Compression forming process in which work metal is forced to flow through a die
opening to produce a desired cross-sectional shape
Extrusion
Process is similar to squeezing toothpaste out of a toothpaste tube
In general, extrusion is used to produce long parts of uniform cross sections

A solid ram drives the entire billet to and through a stationary die and must provide
Direct Extrusion additional power to overcome the frictional resistance between the surface of the
moving billet and confining chamber.

also called reverse, backward, or inverted extrusion; a hollow ram pushes the die back
indirect extrusion
though a stationary, confined billet

Variety of shapes possible, especially in hot extrusion

Limitation: part cross section must be uniform
throughout length
Advantages of Extrusion
Grain structure and strength enhanced in cold and warm extrusion
Close tolerances possible, especially in cold extrusion
In some operations, little or no waste of material

prior heating of billet to above its

recrystallization temperature
Hot extrusion Reduces strength and increases ductility of the
metal, permitting more size reductions and more
complex shapes

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generally used to produce discrete parts

Cold Extrusion
The term impact extrusion is used to indicate high speed cold extrusion

Cross section of a bar, rod, or wire is reduced by pulling it through a die opening
Wire and Bar Bending -similar to extrusion except work is pulled through die in drawing
-It is pushed through in extrusion

Drawing practice:
Usually performed as cold working
Most frequently used for round cross sections

Products:
Drawing Practice and Products
Wire: electrical wire; wire stock for fences, coat
hangers, and shopping carts
Rod stock for nails, screws, rivets, and springs
Bar stock: metal bars for machining, forging, and
other processes

Accomplished as a single-draft operation - the stock is pulled through one die opening
Bar Drawing Beginning stock has large diameter
and is a straight cylinder

`a process in which wire stock is drawn through one or more tapered dies to the
Wire drawing
desired cross section

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