HOT WORKING PROCESS

COLD WORKING PROCESS

FORGING PROCESS
ROLLING PROCESS
EXTRUSION
DRAWING
1. Rolling – slab or plate is squeezed
between 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
HOT WORKING OF METALS
 Hot working refers to the process where
metals are deformed above their
recrystallizatıon temperature but below
the melting point and strain hardening
(Increasing the hardness and tensile
strength of a metal by plastic
deformation)does not occur.
TYPES OF HOT WORKING PROCESS

Hot forging Hot forging

Hot rolling  Hammer forging

Hot extrusions  Drop forging

Drawing  Upset forging

Swaging  Press forging

Hot spinning  Roll forging

 ADVANTAGES
 Force requirement is less.
 Toughness ,ductility, resistance can be improved.
 It is quick process.
 Density of the metal is increased.
DISADVANTAGES
 Tooling and handling cost are high.
 Sheets and wires cannot be produced.
 Difficult to control the temperature of the
workpiece.
 Surface finish may be poor due to scaling.
 COLD WORKING OF
METALS
 Cold working refers to the process
where metals are deformed below
their recrystallizatıon temperature.
 Recrystallizatıon Temperature

The minimum temperature at which

the complete recrystallizatıon of a metal
takes place with in a specified time.
The recrystallizatıon temperature is
about one half of the absolute melting
temperature.
 MATERIALS

 Low and medium carbon steel

 Copper and light alloys

 Aluminium

 Titanium

 Magnesium
CLASSIFICATION OF COLD WORKING

Cold
working
process

Drawing Squeezing Bending

 Drawing

Blank Wire Tube Metal

Embossing
drawing drawing drawing spinning
 Squeezing

Coining Sizing Swaging Knurling Extrusion

 Bending

Plate Roll Angle

Seaming
Bending Bending Bending
 ADVANTAGES
 Good surface finish is obtained
 Provides higher dimensional accuracy
 Thin material can be obtained
 Suitable for mass production
DISADVANTAGES
 Impurities are not removed
 Stress formation is higher
 Close tolerance cannot be achieved
 Hot working
Working above
recrystallization temperature
New crystals are formed
Harden the metal
Impurities are removed
Elongation of metals takes
place
Large size metals also
deformed
Surface finish is not good
Blowholes, Cracks get welded
Internal stress is not
formed
Cold working
Working below
recrystallization temperature
No crystallization
No hardening
Impurities are not removed
Elongation decreases
Limited to size
Good Surface finish
Ductility is obtained, useful
for machining process
Stress is formed
 FORGING PROCESSES
In this process, the desired shape is obtained
by the application of a compressive force.
Types of forging:
1) Smith forging or open die forging
a) Hand forging
b) Power forging ---Hammer, Power
Press forging
2)Closed die or impression forging
a) Drop forging
b) Press forging
c) Upset forging
3)Roll forging
 OPEN DIE FORGING
 Is the simplest forging process
 Sizes can very from very small parts to
very large parts
 OPEN DIE FORGING
 In this process forging is done in heated
work at the proper temperature by placing
on flat surface of hand mill through
hammering the metal piece
 Application – U bolt , chisel , rectangular,
circular ,hexagonal shape
IMPRESSION-DIE (CLOSED-DIE FORGING)
 The work piece acquires the shape of the die
cavities while being forged between the two
shaped dies
Drop forging
Application:
Used for making
Spanner
Automobile parts
Machine parts
Drop forging
PRESS FORGING
 Application:
Used for making
Spanner
Connecting Rod
Machine parts
 UPSET FORGING

(1) wire stock is fed to the stop

(2) gripping dies close on the stock and the stop is
retracted
(3) punch moves forward
(4) bottoms to form the head.
 ROLL FORGING
Deformation process in which work thickness
is reduced by compressive forces exerted by
two opposing rolls
 COMPARISON
PRESS FORGING DROP FORGING
Faster process Slow process
Alignment of Dies is easier Alignment of Dies is
difficult
Quite operation Noisy operation
Structural Quality of the Not Superior
product is superior
Simple maintenance Maintenance is difficult
High output It require skilled operator
Ram speed is high Ram speed is low
One stroke is enough for More than One stroke is
making one component enough for making one
component
 Process Advantages Disadvantages
Open die Useful for small Difficult to hold
quantities. close tolerances.
Inexpensive dies. Low production
Simple and wide range rate.
of sizes. Limited to simple
Good strength. shapes
Closed die Provides good Machining
dimensional accuracy. process is
High production rates. necessary.
Good utilization of Die cost is high
material. for small
Good reproducibility. quantities.
 TYPES OF FORGING MACHINES

POWER
HAMMER

Mechanical Air Hammer Steam Hammer

Hammer (5 to 6 kgf/cm2) (6 to 8 kgf/cm2)

Lever
Helve Trip Pneumatic
Spring
Hammer Hammer Hammer
Hammer
(5 to 200kg) (5 to 200kg) (50 to 1000kg)
(30 to 250 kg)
HELVE HAMMER
LEVER SPRING HAMMER
STEAM HAMMER
PNEUMATIC HAMMER
PNEUMATIC HAMMER
TYPES OF FORGING OPERATION

 Upsetting  Forge welding

 Drawing Down  Piercing
 Punching  Swaging
 Bending  Flattering
 Cutting  Fullering
 ROLLING
Deformation process in which work thickness is
reduced by compressive forces exerted by two
opposing rolls
ROLLED PRODUCTS MADE OF STEEL

Some of the steel products made in a rolling mill.

FLAT ROLLING
 Rolling Mills
Rolling mill configurations:
 Two-high – two opposing rolls
 Three-high – work passes through rolls in
both directions
 Four-high – backing rolls support smaller
work rolls
 Cluster mill – multiple backing rolls on
smaller rolls
 Tandem rolling mill – sequence of two-
high mills
TWO-HIGH ROLLING MILL
THREE-HIGH ROLLING MILL
FOUR-HIGH ROLLING MILL
SHAPE ROLLING
RING ROLLING
 EXTRUSION
In this process the heated metal is
compressed and forced through a
suitable shape die.
Major extrusion defects:
Surface cracking
Piping
Internal cracks
 TYPES OF EXTRUSION
EXTRUSION Cold extrusion
Hot extrusion

Direct extrusion Indirect

extrusion
DIRECT EXTRUSION
HOLLOW AND SEMI-HOLLOW SHAPES

(a) Direct extrusion to produce a hollow or

semi‑hollow cross sections; (b) hollow
(c) semi‑hollow cross sections.
 INDIRECT EXTRUSION

Indirect extrusion to produce (a) a solid

cross section and (b) a hollow cross
section.
 IMPACT EXTRUSION
 Similar to indirect extrusion
 Punch descends rapidly on the blank, which is
extruded backward
HYDROSTATIC EXTRUSION
TUBE PIERCING
TYPES OF TUBE PIERCING
TUBE EXTRUSION
TUBE MANUFACTURING
 DRAWING
1)wire drawing
2)Rod drawing
3)Tube drawing---tube sinking, tube mandrel,
tube plug
4)Deep drawing
DEEP DRAWING
 EQUIPMENTS USED IN DRAWING

TYPES :
 Draw bench:

It contains a single die and it is similar to

a long horizontal testing machine
 Bull block:

It is used to make very long rod and wires

in smaller cross sections
DRAW BENCH
BAR DRAWING BENCH
WIRE DRAWING MACHINE (OR)
BULL BLOCK
DEFECTS IN ROLLED PARTS

 Surface defects
 Internal surface defects
 SURFACE DEFECTS

It includes scale, rust, scratches,

cracks and pits
 It is due to the impurities and
inclusions in the original cast
material
INTERNAL SURFACE DEFECT

 Wavy Edges

 Zipper cracks

 Edge cracks

 Folds

 Alligatoring

 Laminations
 Wavy edges and Zipper cracks occurs
due to bending of rolls
 Zipper cracks occurs due to poor
material ductility at the rolling
temperature (To avoid this Diameter of
roll is made slightly larger at the centre
than the edges)
 Edge cracks are due to poor ductility of
work material
 Fold is created during plate rolling if the
reduction per pass is very small
 Alligatoring is a non-uniform
deformation which occurs due to
piping and inhomogenity

 Lamination occurs due to incomplete

welding of pipe and blowholes during
the rolling process