19AUOC1001

Automotive Fundamentals and

Manufacturing
Online Lecture-29

BHARATHIRAJA R
ASSISTANT PROFESSOR [MECH]
Dr.Mahalingam College of Engineering &
Technology - Pollachi

Dept of Mech 19AUOC1001-AFM

 Course Type : Open Elective Course Categories : Mastery Courses

Total Hours-45 IIIrd Year

[2019-2023 Batch]

Dept of Mech 19AUOC1001-AFM

 Course Outcome
Identify the manufacturing processes for the given
automotive products and explain the manufacturing
process for automotive products.

Learning Outcome 2
Explain Forging process

•Explain the Forging operation in the manufacturing

process.

Dept of Mech 19AUOC1001-AFM

 UNIT V
MANUFACTURING OF
AUTOMOTIVE
PRODUCTS

Dept of Mech 19AUOC1001-AFM

 Forming

Any process that changes the shape of a raw stock

without changing its phase

Example products:
Al/Steel frame of doors and windows, coins, springs,
Elevator doors, cables and wires, sheet-metal, sheet-metal parts…

Dept of Mech 19AUOC1001-AFM

 Rolling

Hot-rolling

Cold-rolling

Dept of Mech 19AUOC1001-AFM

 Rolling

Important Applications:

Steel Plants,
Raw stock production (sheets, tubes, Rods, etc.)
Screw manufacture

Dept of Mech 19AUOC1001-AFM

 Rolling Basics

Sheets are rolled in multiple stages.

tf Vf Vf
to to tf
Vo
Vo

stationary die

Screw manufacture:
rolling die
thread rolling machine

Reciprocating flat thread-rolling dies

Dept of Mech 19AUOC1001-AFM

 Forging
[Heated] metal is beaten with a heavy hammer to give it the required shape

Hot
forging,

open-die

Dept of Mech 19AUOC1001-AFM

 Stages in Open-Die Forging

(a) forge hot billet to max diameter

(b) “fuller: tool to mark step-locations

(c) forge right side

(d) reverse part, forge left side

(e) finish (dimension control)

[source:www.scotforge.co]
Dept of Mech 19AUOC1001-AFM
 Stages in Closed-Die Forging

(a)

(b)

Flash
(c)

1. Blank (bar) 2. Edging 3.Blocking 4. Finishing 5. Trimming

[source:Kalpakjian & Schmid]

Dept of Mech 19AUOC1001-AFM

 Quality of forged parts

Surface finish/Dimensional control:

Better than casting (typically)

Stronger/tougher than cast/machined parts of same material

[source:www.scotforge.com]

Dept of Mech 19AUOC1001-AFM

 Extrusion

Metal forced/squeezed out through a hole (die)

[source:www.magnode.com]

Typical use: ductile metals (Cu, Steel, Al, Mg), Plastics, Rubbers

Common products:

Al frames of white-boards, doors, windows, …

Dept of Mech 19AUOC1001-AFM

 Extrusion: Schematic, Dies

chamber die

extruded shape
hydraulic
stock
piston

chamber

Dept of Mech 19AUOC1001-AFM

 Drawing

Similar to extrusion, except: pulling force is applied

stock (bar) die

wire

F (pulling force)

Commonly used to make wires from round bars

Dept of Mech 19AUOC1001-AFM