Nyersvas- és acélgyártás · Thread rolling Reciprocating flat dies Roller dies. Seamless tubes...
Transcript of Nyersvas- és acélgyártás · Thread rolling Reciprocating flat dies Roller dies. Seamless tubes...
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Metals Technology
Forming II.
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• Rolling
• Forging
• Extrusion
• Sheet metal forming
Today’s topic
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Rolling techniques
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Flat rolling
Material’s flow in the rolling gap
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Flat rolling
Rolling arrangement
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Flat rolling
Bending of the rolls
Hot rolling, recrystallisation
Cylindrical rolls Rolls with camber
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Flat rolling - defects
Wavy edges Cracks in the center
Edge cracks Aligatoring
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Shape (caliber) and ring rolling
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Thread rolling
Reciprocating flat dies
Roller dies
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Seamless tubes and pipes by rolling
Cavity formation in a solid round bar
Rotary tubepiercing process
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Seamless tubes and pipes by rolling
different techniques
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Forging techniques
Cold warm and hot forging depending on the temperature
Grain flow control
Open die Closed die
+Simple and inexpensive dies
+Small quantity
-Limited to simple shapes
-low production rate
-high degree of skill required
+Relatively good utilization of material;
+better properties than open-die
forgings
+dimensional accuracy;
+high production rates;
+good reproducibility
-High die cost
-not economical for small quantities
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(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.com]
Open die forging - stages
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Closed die forging
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Forge rolling
Closed die forging
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Closed die forging
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Trimming flash from a forged part.
Closed die forging
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1. Prepare a slug, billet, by shearing, sawing, or cutting.
(clean surfaces e-g by shot blasting)
2. For hot forging, heat the workpiece in a furnace and then descale it
(wire brush, water jet, or steam)
3. For hot forging: preheat and lubricate the dies
For cold forging: lubricate the blank
4. Forge the billet in dies and in the proper sequence.
(+ metarial removal (e.g.flash) by trimming, machining, or grinding.
5. Clean the forging and the dimensions
6. Additional operations: straightening, heat treating
7. Machining and grinding to final dimensions and specified tolerances.
8. Inspection: external and internal defects.
Closed die forging – technology sequence
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Forging – grain flow
Quality of forged parts
Surface finish/Dimensional control: Better than casting (typically)
Stronger/tougher than cast/machined parts of same material
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Forging - defects
Temperature controll: temperature decreases → cracks
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Extrusion processes
Hot and cold extrusion
Forward and backward extrusion
Extrusion of other shapes
Drawing of rod and wire
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Forward extrusion
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Extrusion of a seamless tubes
using an internal mandrel
using a spider die
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Impact extrusion
cold extrusion process
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Extrusion - defects
Surface Cracking stick-slip - bamboo defect
Pipe (fishtail) defect Internal cracking
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Drawing
The cross section of a long rod or wire is reduced or changed by
pulling it through a draw die.
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Drawing of pipe
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Drawing of wire
Multistage wire drawing
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Shearing
Formability
Bending Sheets, Plates,
and Tubes
Sheet metal forming
Deep Drawing
Rubber Forming and
Hydroforming
Spinning
Superplastic Forming
Specialized Forming Processes
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Shearing
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Shearing
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Shearing – fine blanking
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Shearing – punching and blanking
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Shearing – Slitting with rotary knives
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Shearing – Tailor welded blanks
Production of an outer side panel of a car body
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Formability of metal sheets
Forming limit diagram
cracksa
fe
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Bending of sheets pipes and tubes
Springback in bending
(recovers elastically)
overbendingDefects
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Bending of sheets
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Bending of pipes, tubes
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Deep drawing
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Deep drawing - defects
Flange wrinkling Cracking EaringWall wrinkling
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Beverage can – production steps
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Beverage can – production steps
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Ruber forming
The outer surface of the sheet is protected from damage or scratches: no
contact with a hard metal surface during forming.
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Hydroforming
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Spinning
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Spinning
Shear-spinning
Tube-spinning