THE AMERICAN UNIVERSITY IN CAIRO

MENG 3209/339
Fundamentals of Manufacturing Processes

Lab Report 5: Bulk Deformation

Submitted by: Cherif Youssef Chokeir

SID: 900140712

Date of Submission: 22/3/2017

Dr. AbdAllah Wifi

Ta. Kirolos Bastawros

Abstract:
The purpose of this report is to study two metal forming processes: forging and rolling. Forging

could be understood as metal working process in which the material is held between a hammer or

punch and die that help in obtaining special types of products and surface features impossible to

obtain by any other means. Rolling is a process that helps in obtaining thin sections by putting a

sheet of metal between two main rollers cylinders. . Each type of these operations is being

studied with a good understanding of the process after discussing the overview of the metal

forming processes.
Table of Contents:
List of figures4
Introduction And Background.5
Objective7
Experiment Description and Analysis8
Conclusions and Recommendations...........13
List of figures

Figure 1 Example of products best obtained by bulk deformation and metal working ............................... 6
Figure 2 Open die Forging (Groover) ............................................................................................................ 8
Figure 3 Open die forging operation............................................................................................................. 9
Figure 4 Drop hammer used for open die forging ........................................................................................ 9
Figure 5 Specimens Used for open die forging (TOP: Greased Bottom: without grease) .......................... 10
Figure 6 Data for the lubricated and non-lubricated specimens. ............................................................... 10
Figure 7 %Reduction in height vs. energy of falling weight for both lubricated and non-lubricated
specimens ................................................................................................................................................... 11
Figure 8 Closed die forging: (1) just prior to initial contact with raw workpiece, (2) partial compression,
and (3) final die closure, causing flash to form in gap between die ........................................................... 13
Figure 9 Die used in closed die forging ....................................................................................................... 14
Figure 10 Rolling process and the effect on the materials structure. ....................................................... 15
Figure 11 The specimen after the rolling operation .................................................................................. 17
Figure 12 4 high rolling mills ....................................................................................................................... 17
Figure 13 2 high rolling mills ....................................................................................................................... 17

List of Tables
Table.1 Energy as function of hammer height11
Table.2 Energy vs %reduction in height for lubricated and non-lubricated specimen12

Table.3 Modified Dimensions for the sheet.16

Introduction and Background:
Bulk forming are a series of manufacturing processes that are intended to produce wrought parts

characterized by their extra strength and toughness, when compared to cast products that are

produced by casting. Some engineering applications require the use of these wrought metals and

alloys like critical structural parts located in bridges for example and pressure vessels or piping

systems used in buildings.

Generally speaking, working of metals has two important causes. At first, these processes help in

producing products in variety of shapes that would be expensive and difficult to produce using

other manufacturing processes. Examples of such products include I-sections as well as rails, but

also thin sheets and wire. At second, this working of metals usually enhances the mechanical

properties of the materials.

To further discuss this point, it is important to understand that the main improvement in the

mechanical properties is made via grain refinement by recrystallization, directional control of

flow lines, homogenization of cored structure, to break up in order to redistribute the

irregularities in the structure of the metal and then close up with welding of porous medium.

The common feature that is encountered in all these metal working processes is the grain flow, which

therefore must be taken into consideration by the designer, as the best mechanical properties are met

in the grain flow direction, and local variations of these grain flow might greatly affect the

mechanical properties.
Metal working is generally classified into two broad categories: hot working, which corresponds to

forming the metal above recrystallization temperature but below its melting point. On the other hand,

forming at low temperatures is called cold working. There is a third process corresponding to

working the metal in between called warm working. As a rule of thumb, for hot working metals, this

corresponds to a temperature of 0.5 Tm where Tm is the absolute temperature of melting of the

metal. The general properties obtained are softness and ductility. For cold worked metals, they are

generally less in their ductility and more strain hardened. For these reasons, the hot working of

metals are generally performed in the semi-finishing phases of the production sequence. On the other

hand, cold working is generally employed in the finishing phases and that is to take complete

advantage of the improvement in the strength, closer dimensional tolerance and surface finish.

Figure 1 Example of products best obtained by bulk deformation and metal working
Objectives:
- Understand and get an overview of metal forming processes

- Understand and study the process of forging

- Understand and study the process of rolling

- Perform the forging and rolling operations

- Understand and study different parameters affecting these processes.

- Compare between different machining processes in terms of advantages and

disadvantages.
Experiment Description and Analysis
Forging:

Historically speaking, forging is the oldest form of metal working process. Throughout the centuries,

a wide variety of different processes had been made in order to have important flexibility, in terms of

applications to both single and mass productions. There different types of forging machines including

power hammers and presses, which are used to apply compressive forces that are needed for the

forging process. There are two main types of forging processes based on the type of die that is used.

1. Open Die forging :

This kind of forging operation is mainly used for large parts that are made in small numbers. It is
a cheaper forging process than closed die forging since the cost of the tools used in this operation
are generally low. However, the disadvantages of such a process lies in the fact it is less accurate
than closed die forging, and the fact it requires a skilled labor and it has slower rates of
production than closed die forging.

Figure 2 Open die Forging (Groover)

Figure 3 Open die forging operation

Experimental Procedures
1. Use the drop hammer to forge 4 non-lubricated lead specimens from 4 different
heights: 30, 60, 90, 120 cm.

Figure 4 Drop hammer used for open die forging

.

Figure 5 Specimens Used for open die forging (TOP: Greased Bottom: without grease)

2. Measure the initial and final heights and diameters for each case.
3. Use a drop hammer to forge 4 lubricated lead specimens from 4 different heights: 30,
60, 90, 120 cm.
4. Measure the initial and final heights and diameters for each case.

Figure 6 Data for the lubricated and non-lubricated specimens.

5. Calculate the weight of the drop hammer.
W = m*g =58 *9.81 = 568.98 N
6. Calculate the energy of the blow for each of the heights used.
Height (cm) Energy (J)
30 17069.4
60 34138.8
90 51208.2
120 68277.6
Table.1 Energy as function of hammer height
Thus the energy and therefore the compressive forces increase with the height.
7. Plot the reduction in height of the specimen versus the energy of the falling weight
for both cases.
45
40
35
%Reduction in height

30
25
20 Non Lubricated

15 Lubricated

10
5
0
0 20000 40000 60000 80000
Energy (J)

Figure 7 %Reduction in height vs. energy of falling weight for both lubricated and non-lubricated specimens

It is apparent that for lubricated specimen the reduction in height vs the energy of the weight is less

than the non-lubricated specimens. This is due to the fact that lubrication reduces the impact of the

hammer on the specimen.

8. Compare between lubricated and non-lubricated specimens:

a. Barreling

From fig.6, it is apparent that the pattern for the non-lubricated specimen is that the diameter is

always larger in the middle portion, characteristic of a barrel-shape which is not the case for the

lubricated specimen. Explication of this phenomenon is that the malleability of the lead specimen

without grease is larger than its malleability with grease. In fact the percentage reduction in length

as well as the percentage increase in the area show that the grease decreases the malleability of the

lead. Malleability is the property of the material to deform and take various shapes under

compression. (Malleable). Therefore, lead could deform and take different shapes better without

grease than with grease.

b. % Reduction in height

Energy(J) %Reduction in height Non-lubricated

17069.4 16.66666667
34138.8 26.66666667
51208.2 32
68277.6 41

%Reduction in
Energy(J) height(Lubricated)
17069.4 18.5
34138.8 21.33333333
51208.2 33
68277.6 41.16666667
Table.2 Energy vs %reduction in height for lubricated and non-lubricated specimen

It is apparent that for lubricated specimen the reduction in height vs the energy of the weight is less

than the non-lubricated specimens. This is due to the fact that lubrication reduces the impact of the

hammer on the specimen. Also this could be explained by the fact that grease reduces the

malleability of the lead.

9. Sketch the experimental setup, identifying the different parts and their functions.

N.B. The experiment will be carried out on lead specimens, simulating hot forging. Care

must be taken while handling lead since it is poisonous.

2. Closed Die Forging :

In this process, the forging operation is performed in a closed die, which enhances the

flexibility in the design of the product, and permits complex shapes with closer

dimensional tolerances and with automation of the process, the labor costs are thus

reduced and the reproducibility is improved.

Figure 8 Closed die forging: (1) just prior to initial contact with raw workpiece, (2) partial compression, and (3) final die closure,
causing flash to form in gap between die
Figure 9 Die used in closed die forging

The most important remark to note here is that there is no change in diameter for this

process. No Barrel shape is obtained.

 Rolling
Rolling is a manufacturing process that is used in order to obtain large number of flat thin sheets,

plates or strips, but also structural shapes like angles, rails and channels. Examples of products also

contain rods, bars and related parts. Hot rolling is the most widely used manufacturing process in

terms of total tonnage. However, the disadvantage is that parts are limited in sizes and shapes that are

suited to the market demand. The control of the properties of the products of this operation is done by

controlling the rolling schedule and finishing temperature. Hot rolled products are usually finished by

cold rolling in order to enhance their mechanical properties, dimensional accuracy and surface finish.

Figure 10 Rolling process and the effect on the materials structure.

Experimental Procedures
1. Measure the initial dimensions of the given aluminum samples (length, width and
thickness)
Dimensions Value
Length 20 cm
Width 10 cm
Tickness 5.85 mm

2. Calculate the roll gap that will give a 15% reduction in height.
0.25 mm
3. Measure the dimensions of the deformed specimen.
Dimensions Value
Length 20.6 cm
Width 10 cm
Tickness 5.70 mm

4. Give the specimen five more passes of about 15% each.

5. Measure the dimensions of the specimen after each pass.
Dimensions Value Value (10%- Value (10%- Value Value
(10%- 2rev) 2rev) (10%- (20%-4rev)
2rev) 2rev)
Length 22.1 24.2 cm 27 cm 30.6 cm -
cm
Width 10 cm 10 cm 10.1 cm 10.3 cm -
Tickness 5.30 4.8 mm 4.3 mm 3.8 mm 2.9 mm
mm
Table.3 Modified Dimensions for the sheet
6. Plot the coefficient of spread, S, versus the total % reduction in height, where

where W0 & W1 are widths of undeformed and deformed samples, and H0 & H1 are the
thicknesses of undeformed and deformed samples.

Series 1
0.2

0.15

0.1
S

0.05

0
0 10 20 30 40 50 60
-0.05
%reduction in height

Series 1

Fig. 11 Coefficient of spread vs %reduction in height

It appears from the above diagram that the spread coefficient is at first almost zero for the first %
reduction in height, it increases afterwards after almost 30% reduction in height. This shows that
the specimens width increases at the end of the deformation Rolling process, which is
characteristic of this kind of operation.
7. Comment on the shape of the sample after rolling and discuss the results.
After rolling, the sample becomes almost flat. Its thickness had reduced too much it is now in the
shape of thin flat strip or sheet. This shows the capability of this kind of manufacturing process since
it permits production of very thin sections, which could not be produced by any other method. The
shape of the specimen is shown in fig. 12

Figure 11 The specimen after the rolling operation

8. Draw the 4-high and 2-high rolling mills, identifying the different parts and their
functions.

Figure 12 4 high rolling mills

Figure 13 2 high rolling mills

 Conclusion and Recommendations:

To sum up, in this experiment, the purpose was to study two metal forming processes: forging

and rolling and their advantages. After understanding the main principle behind metal forming

operations, it had been possible to understand forging operations and that they are performed

in either open or closed die which help in producing parts of complex geometries and features

and with good dimensional accuracy and surface finish. Special emphasis had been made on

the fact that open dies are cheaper but less accurate than closed die. Furthermore, the rolling

operation help in producing products with very small thickness impossible to obtain by other

means. Open die forging process had been found to cause barrel-shape formation which is not

encountered in closed die forging. Furthermore, the thickness of the sheet metal obtained by

rolling had been found to increase at the end of the rolling process.

It is further recommended that the lab responsible would possibly in the future offer other

types of metal forming processes to compare different processes and their relative advantages

and disadvantages.
References

Groover Funfamentals of Modern Manufacturing. John Wiley and Sons 2010

Lab notes AUC

Malleable. In Merriam Webster dictionnary Retrieved Oct. 11, 2015 from

http://www.merriam-webster.com/dictionary/malleable