06-Bulk Deformation Processes [Compatibility Mode]

06-Bulk Deformation Processes [Compatibility Mode] -...

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Chapter 6 Bulk Deformation rocesses Manufacturing Processes Prof. T. Özel Processes
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Manufacturing Processes: Forming and Shaping Extrusion/Drawing Manufacturing Processes Prof. T. Özel Schematic illustration of various bulk deformation processes
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BULK DEFORMATION PROCESSES -METAL FORMING- Billet Discrete Useful Part •Simple Shape •Material •Complex Shape •Size / Appearance •Accuracy / Tolerances Manufacturing Processes Prof. T. Özel •Properties Process Capabilities •Geometry •Tolerances / Dimensional Quality •Production Rate •Product Properties / Quality •Environmental Factors
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METAL FORMING Metal forming is attractive when; a) moderate part complexity and large production volume are involved, b) mechanical and metallurgical properties are very portant. Manufacturing Processes Prof. T. Özel important. Design of metal forming processes require; a) analytical knowledge on metal flow, stresses, heat transfer, and b) technological information related to lubrication, heating & cooling, part handling, dies & equipment
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Bulk-Deformation Processes PROCESS GENERAL CHARACTERISTICS Forging Production of discrete parts with a set of dies; some finishing operations usually necessary; similar parts can be made by casting and powder-metallurgy techniques; usually performed at elevated temperatures; dies and equipment costs are high; moderate to high labor costs; moderate to high operator skill. Rolling -Flat Production of flat plate, sheet, and foil at high speeds, and with good surface finish, especially in cold rolling; requires very high capital investment; low to moderate labor cost. -Shape Production of various structural shapes, such as I-beams and rails, at high speeds; includes thread and ring rolling; requires shaped rolls and expensive equipment; low to Manufacturing Processes Prof. T. Özel TABLE 6.1 General characteristics of bulk deformation processes. moderate labor cost; moderate operator skill. Extrusion Production of long lengths of solid or hollow products with constant cross-sections, usually performed at elevated temperatures; product is then cut to desired lengths; can be competitive with roll forming; cold extrusion has similarities to forging and is used to make discrete products; moderate to high die and equipment cost; low to moderate labor cost; low to moderate operator skill. Drawing Swaging Production of long rod, wire, and tubing, with round or various cross-sections; smaller cross-sections than extrusions; good surface finish; low to moderate die, equipment and labor costs; low to moderate operator skill. Radial forging of discrete or long parts with various internal and external shapes; generally carried out at room temperature; low to moderate operator skill.
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Bulk Deformation Processes -Metal Forming- Billet Forging Rolling Manufacturing Processes Prof. T. Özel Rod/Wire Drawing Extrusion
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Forging •Forging denotes a family of processes by which deformation of the workpiece is carried out by compressive forces applied through dies. •Forging is capable of producing a wide variety of parts with favorable
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This note was uploaded on 09/20/2011 for the course ENG 303 taught by Professor Any during the Fall '08 term at Rutgers.

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06-Bulk Deformation Processes [Compatibility Mode] -...

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