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Manufacturing Processes
Rahul Panat
Deformation Processes - II
Week 6
OUTLINE
Rolling Processes
Different Rolling Operations
Mechanics of Rolling
Slab Analysis for Rolling
Pressure Distribution in Rolling
Defects in Rolling
ROLLING
Slabs are a rectangular solid with a width greater than twice the
thickness.
Flat rolling
Shape rolling
Videos:
https://www.youtube.com/watch?v=
AuuP8L-WppI -0-1.5min
http://www.youtube.com/watch?ann
otation_id=annotation_280168&feat
ure=iv&src_vid=AuuP8LWppI&v=k6iODHla6qY 0-1min
http://www.youtube.com/watch?v=6xnKmt_gsLs
MECHANICS OF ROLLING
Friction is important
Neutral point
Vr=Vworkpiece (no slip
point)
Direction of friction is
different across the
neutral point
Desired to be close to exit
R
Forward slip:
Draft, h0 hf =
m2R
http://www.youtube.com/watch?v=Kg1FIIaEwEE
Frictional forces
Pressure distribution as a
function of front and back
tension in rolling. Note the
shifting of the neutral point
and the reduction in the
area under the curves
(hence reduction in the roll
force) as tensions
increase.
DEFECTS IN ROLLING
Wavy edges
Zipper cracks in the
center of strip
Edge cracks
Alligatoring
Residual stress
ROLLING PROCESSES
Skew Rolling
Roll Forging
Thread Rolling
QUESTIONS?
REVIEW QUESTIONS
Rolling is a bulk deformation process in which the thickness of
the work is reduced by compressive forces exerted by two
opposing rolls:
(a) true
(b) false
REVIEW QUESTIONS
The maximum possible draft in a rolling operation depends on
which of the following parameters (two correct answers):
(a) coefficient of friction between roll and work,
(b) roll diameter,
(c) roll velocity,
(d) stock thickness,
(e) strength coefficient of the work metal
Draft, h0 hf = m2R
EXTRUSION
Metal is compressed and forced to flow through a shaped die to
form a product with a constant cross section
May be performed hot or cold
A ram advances from one end of the die and causes the metal to
flow plastically through the die
Commonly extruded metals: aluminum, magnesium, copper, and
lead
RAM
TYPES OF EXTRUSION
Direct Extrusion
Indirect Extrusion
Hydrostatic extrusion
Impact extrusion
ADVANTAGES OF EXTRUSION
Many shapes can be produced that are not possible with rolling
Amount of reduction in a single step is only limited by the
equipment, not the material or the design
Dies are relatively inexpensive
Small quantities of a desired shape can be produced
economically
Video Time!
Direct Extrusion
http://www.youtube.com/watch?v=9MqzKihSrFI
Impact Extrusio
http://www.youtube.com/watch?v=zMhVPId-pRA
EXTRUDED PRODUCTS
A0
)
Af
http://www.youtube.com/watch?v=QKAg1yMZIpY
http://www.youtube.com/watch?v=zlueIHudt4k
A
m
2
d Y [(1 ) ln( 0 ) ]
Af
3
ROTARY SWAGING
A process in which a rod or tube is reduced in diameter by the reciprocating
radial movement of two or four dies (external hammers)
Reduce diameter
Produce taper or add point
SWAGING OPERATIONS
Swaging process animation
o http://www.youtube.com/watch?v=ilL8ViUDUKc
Reduction of outer and inner diameters of tubes by swaging. (a) Free sinking
without a mandrel. The ends of solid bars and wire are tapered (pointing) by
this process in order to feed the material into the conical die. (b) Sinking on a
mandrel. Coaxial tubes of different materials can also be swaged in one
operation.
SWAGED PRODUCTS
SUMMARY
There are a variety of bulk deformation processes
The main processes are
Rolling, forging, extrusion, and drawing