IE 204 Manufacturing Processes

Dr. Zhal ERDEN

FORMING AND SHAPING PROCESSES AND EQUIPMENT

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

CONTENTS
Rolling Forging Extrusion and drawing Sheet-metal forming Powder Metallurgy Forming and shaping plastics and composites; Rapid Prototyping Forming and shaping ceramics and glass
Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

ROLLING

Rolling is the process of reducing the thickess or changing the cross-section of a long workpiece by compressive forces applied through a set of rolls

Flat rolling

Shape rolling

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

Flat Rolling

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

Shape Rolling

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

Applications
Straight and long structural shapes
Solid bars with various cross

sections Channels I-beams Railroad rails

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

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

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

Forging
Forging is the name for processes whereby the workpiece is shaped by compressive forces applied through various dies and tools
Press or forging hammer Discrete parts (bolts and

rivets, connecting rods, shafts for turbines, gears,hand tools, structural components for machinery) Cold forging (at room temperature) Warm or hot forging (at elevated temperatures

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

Open-die forging

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

Impression-die and Closed-die Forging

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

Related forging operations - Heading

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

Piercing

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

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 steels containing chromium, nickel, molybdenum and vanadium
Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

Economics of Forging

Atlm University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes

Dr. Zhal ERDEN

Atlm University / Dept. of Industrial Engineering