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Traditional Manufacturing

Processes

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Forming

Any process that changes the shape of a raw stock

without changing its phase

Example products:

Al/Steel frame of doors and windows, coins, springs,

Elevator doors, cables and wires, sheet-metal, sheet-metal parts

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Rolling

Hot-rolling

Cold-rolling

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Rolling

Important Applications:

Steel Plants,

Raw stock roduction sheets tubes Rods etc.

Screw manufacture

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Rolling Basics

Sheets are rolled in multiple stages (why ?)

Vo

Vfto tf

Vo

Vfto tfVo

Vfto tf

Vo

Vfto tf

thread rolling machine

stationary die

rolling die

thread rolling machine

stationary die

rolling die

Reciprocating flat thread-rolling diesReciprocating flat thread-rolling dies

Screw manufacture:

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Forging

[Heated] metal is beaten with a heavy hammer to give it the required shape

o org ng,

open-die

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Stages in Open-Die Forging

(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] 26RAKESH CHANDER SAINI

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(a)(a)(a)

Stages in Closed-Die Forging

1. Blank (bar) 2. Edging 3.Blocking 4. Finishing 5. Trimming

Flash

(b)

(c)

1. Blank (bar) 2. Edging 3.Blocking 4. Finishing 5. Trimming1. Blank (bar) 2. Edging 3.Blocking 4. Finishing 5. Trimming

Flash

(b)

(c)Flash

(b)

(c)

[source:Kalpakjian & Schmid] 27RAKESH CHANDER SAINI

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Extrusion

Metal forced/squeezed out through a hole (die)

[source:www.magnode.com]

Typical use: ductile metals (Cu, Steel, Al, Mg), Plastics, Rubbers

Common products:

Al frames of white-boards, doors, windows, 29RAKESH CHANDER SAINI

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hydraulic

piston

chamber

chamber

stock

die

extruded shape

hydraulic

piston

chamber

chamber

stock

die

extruded shape

hydraulic

piston

chamber

chamber

stock

die

extruded shape

Extrusion: Schematic, Dies

Exercise: how can we get hollow parts?

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Drawing

stock (bar)

F (pulling force)

wirediestock (bar)

F (pulling force)

wiredie

Similar to extrusion, except: pulling force is applied

Commonly used to make wires from round bars

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AUDI engine block 32RAKESH CHANDER SAINI

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V6 engine block

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BMW cylinder head

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Brake assembly 35RAKESH CHANDER SAINI

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Im ellers

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Crank Shaft

Also see: http://auto.howstuffworks.com/engine7.htm

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