ie204forming(rolling&forging)

7/28/2019 IE204Forming(Rolling&Forging)

1/17

IE 204 Manufacturing Processes Dr. Zhal ERDEN

Atlm University / Dept. of Industrial Engineering

FORMING AND SHAPING PROCESSESAND EQUIPMENT


2/17



CONTENTS

Rolling

Forging

Extrusion and drawingSheet-metal forming

Powder Metallurgy

Forming and shaping plastics andcomposites; Rapid Prototyping

Forming and shaping ceramics and glass


3/17



ROLLING

Flat rolling Shape rolling

Rolling is the process of

reducing the thickess orchanging the cross-sectionof a long workpiece bycompressive forces applied

through a set of rolls


4/17



Flat Rolling


5/17



Shape Rolling


6/17



Applications

Straight and long structural shapes

Solid bars with various cross

sections Channels

I-beams

Railroad rails


7/17



Production of Seamless Tubes and Pipes

Rotary Tube Piercing (The Mannesmann Process)

Hot-working process

Radial compressive forces tensile stress at the center of the bar

Cyclic compressive stresses cavity formation

Diameter of tubes and pipes are reduced by tube rolling


8/17




9/17



Forging

Press or forging hammer

Discrete parts (bolts and

rivets, connecting rods, shafts

for turbines, gears,hand tools,structural components formachinery)

Cold forging (at roomtemperature)

Warm or hot forging (atelevated temperatures

Forging is the name forprocesses whereby the

workpiece is shaped bycompressive forces appliedthrough various dies andtools


10/17



Open-die forging


11/17



Impression-die and Closed-die Forging


12/17




13/17



Related forging operations - Heading


14/17



Piercing


15/17

Die Materials

General requirements for die materials:

Strength and toughness at elevated

temperatures Herdenability and ability to harden uniformly Mechanical and thermal shock resistance Wear resistance (abrasive wear resistance)

Common die materials: tool and die steelscontaining chromium, nickel, molybdenum andvanadium




16/17



Economics of Forging


17/17



ie204forming(rolling&forging)

Documents