1 / 46

Metal Forming Operations

Metal Forming Operations. Rolling: makes sheet metal (hot or cold). Kalpakjian. Forging: makes strong solid parts (hot or cold ). Kalpakjian. Extrusion: makes complex cross-sections from soft metals and plastics (hot). Kalpakjian. www.capalex.com. Wire drawing:

alodie
Download Presentation

Metal Forming Operations

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Metal Forming Operations Rolling: makes sheet metal (hot or cold) Kalpakjian Forging: makes strong solid parts (hot or cold) Kalpakjian

  2. Extrusion: makes complex cross-sections from soft metals and plastics (hot) Kalpakjian www.capalex.com Wire drawing: Makes strong small dia. wire (hot or cold) Kalpakjian

  3. Bending: (2D) Bend sheet metal about single axis (hot or cold) Kalpakjian Deep drawing (3D) Makes “cups” from sheet metal, for mass production. (cold) Kalpakjian

  4. Spinning: Makes “cups” from sheet metal, for lower production. (cold) Kalpakjian Roll forming (Hot): Moves bulk metal, makes I-beams Roll forming (Cold): Bends sheetmetal into complex cross-sections Kalpakjian Kalpakjian

  5. Shearing: Cut or punch sheetmetal (hot or cold) Kalpakjian

  6. Forming • Oriented flowlines decrease fracture risk from grain boundaries, improve strength along flow direction. • (Directional properties). • Especially seen in: • Forging • Rolling • Drawing ASM Metals Handbook Vol.9 Cracks tend to start where grain boundaries intersect surface. Forging minimizes these. Bralla

  7. Thread-rolling for bolts: • Rolled threads stronger than machined (and less expensive) Kalpakjian

  8. Directional Properties in Rolling • Oriented flowlines: • Less ductility when bent in one direction • More ductility when bent in the other Kalpakjian

  9. Slab Production: Hot Rolling Color & Temp www.labware.com www.beautifuliron.com www.falckacciai.it

  10. Progressive Hot Rolling: smaller, uniform grains Kalpakjian

  11. Hot Working:Forging www.smeedwerkunica.nl Open Die Forging T.Green, WIT Paul Berenson, www.paulb.com

  12. Forging Presses Kalpakjian Erie Press Hydraulic press Mechanical press with an eccentric drive: faster Slow but high force and low cost

  13. Knuckle-joint press Screw press Gravity drop hammer: Simplest Forging Presses Kalpakjian

  14. Forging: Closed Die Forging Kalpakjian

  15. Forging: Heat Loss Metal near die surfaces are coolest, flow less www.lft.uni-erlangen.de www.freedomalloysusa.com

  16. Upset Forging (hot or cold) Bolt manufacture Kalpakjian

  17. Roll Forming (hot): I-beams Kalpakjian www.civil.ubc.ca Lunchtime on a Crossbeam, Unknown, www.buffalogames.com

  18. Extrusion (hot or cold): Typ.: Alum., soft metals With special lubes: steels ~Any cross-section Inexpensive dies Good finish en.wikipedia.org T.Green, WIT

  19. Extrusion: Hollow cross-sections: Use Mandrels Kalpakjian www.abra.net.au

  20. Mannesmann Process: Piercing (Hot) Seamless pipe, tube Kalpakjian

  21. Cold-Working (vs. Hot): • Products: • Better tolerances • Much better surface finish • Elongated (and smaller) grains • Turns inexpensive alloys into stronger but less ductile products • Sheetmetal lends itself to cold working, not hot working • Processes: • Higher processing forces • Larger and stronger machinery • Less ductility available • Lower energy use

  22. Cold Rolling:Sheetmetal production finance.pipex.com www.nzsteel.co.nz Kalpakjian

  23. Cold Rolling:Sheetmetal production Cluster rolls support smaller contacting rolls www.sendzimir.com www.elgiloy.com

  24. Cold Rolling:Sheetmetal production Residual Stresses may lead to warping after bar is machined Kalpakjian Large reduction Small reduction

  25. Roll Forming of Sheetmetal (cold) www.cometroll.com www.safeair-dowco.com Kalpakjian

  26. Roll Forming of sheetmetal www.mortonbuildings.com

  27. Punching & Blanking of Sheetmetal Punch Stripper plate Die T.Green, WIT Punching (Scrap) Blanking (Saved: a “blank”)

  28. Punching ofSheetmetal Kalpakjian

  29. Blanking of Sheetmetal: Efficient Nesting of Blanks Kalpakjian

  30. Sheetmetal: Bending Springback: Kalpakjian

  31. Sheetmetal: Minimum Bend Radius Tight radius bends (folds) require metal with ~40% ductility Kalpakjian

  32. Bending of Sheetmetal Use notches to avoid tearing and wrinkling in right-angle bends Kalpakjian

  33. Bending of Sheetmetal Press Brakes: For lower production volumes 10-30 foot long 50-3000 tons www.loomismetals.com

  34. Bending: Press-Brake Operations Kalpakjian

  35. Relative Unit Costs of a Small Connecting Rod For large quantities, forging and die casting are more economical. Sand casting is the more economical process for fewer than about 20,000 pieces. Kalpakjian

  36. Deep Drawing (cold, for sheetmetal) - Punch draws blank into die • Metal is supported on both sides to avoid wrinkling • Hold-down pressure (blankholder force) is primary process variable if too high: tearing if too low: wrinkling www.endo-mfg.co.jp Kalpakjian

  37. Deep Drawing “Draw beads” may be used to control metal flow Kalpakjian

  38. Spinning Ideal for • Lower production volumes • Large parts • Inexpensive tooling www.dissco.co.nz www.ashfordmetalspinning.co.uk www.traditional-building.com

  39. Spinning videos

  40. Cost comparison: manufacturing a round sheet-metal container by spinning and deep drawing. For small quantities, spinning is more economical. Kalpakjian

  41. Finite Element Simulations Predict and minimize tearing and wrinkling locations www.esi-group.com nsmwww.eng.ohio-state.edu tmku209.ctw.utwente.nl

  42. Progressive Stamping Dies Common method to handle complex parts www.nissin-precision.com

  43. Tube-drawing DOM: Drawn Over Mandrel Tubing Seamless Thin wall, tight tolerance, strong Malicky www.twmetals.com “Floating plug” Kalpakjian

  44. Bicycles: Butted DOM tubing Increased wall thickness at ends Reinforces high stress points www.torelli.com materials.npl.co.uk

  45. Diego Rivera, Detroit Industry, Detroit Institute of Art

  46. References Kalpakjian: http://www.nd.edu/~manufact/index3.htm Bralla: James G. Bralla, Design for Manufacturing Handbook, McGraw-Hill, 2nd Edition. In: www.rose-hulman.edu/~stienstr

More Related