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Metal Forming
Metal forming processes can be
classified in two grubs. These are as
followed
1. Cold working is the plastic deformation of
metal below the recrystallization temperature.
In same cases of manufacturing, such cold
working may be done at room temperature.
2. Hot working is defined as the plastic
deformation of metals above the
recrystallization temperature.
Cold Working
No heating is required
Better surface finish is obtained
Superior dimension control
Better reproducibility
Improved strength properties
Directional properties can be imparted
Contamination problems are minimized
Cold Working
Some disadvantaged
1. Higher force are required for deformation
2. Heavier and more powerful equipment is
required
3. Less ductility is available
4. Metal surface must be clean and scale-free
5. Strain hardening occurs
6. May produce undesirable residual stresses
Rolling of Metals
Rolling of Metals
Rolling reducing the thickness or changing the crosssection of a long workpiece by compressive forces
applied through a set of rolls
Developed in late 1500s
Accounts for 90% of all metals produced by metal
working processes
Often carried out at elevated temperatures first (hot
rolling) to change coarse-grained, brittle, and porous
ingot structures to wrought structures with finer grain
sizes and enhanced properties
Flat Rolling
Initial thickness ho
Final thickness hf
Roll gap L
Flat Rolling
Draft: ho hf
Maximum draft possible: ho hf = 2R
Coefficient of friction
Roll radius R
Flat Rolling
Flat Rolling
R h0 h f
Contact length
L
Average flow stress:
Y k n
f
Yave
In rolling:
n
k
d
0
f (n 1)
n 1
h0
f ln
hf
f
k
n 1
Defects in Rolling
Rolling Mills
Figure 13.11 Schematic illustration of various roll arrangements: (a) two-high; (b) three- high; (c) fourhigh; (d) cluster (Sendzimir) mill.
Tandem Rolling
Tandem Rolling
Stage 2
Stage 1
w0
h0
V0
Stage 3
Stage 4
w1
w2
w3
wf
h1
h2
h3
hf
V1
V2
V3
Vf
Volume conserved
h0 h1 h1 h2 h2 h3 h3 h f
h0
h3
h1
h2
ln ln ln ln
h1
h2
h3
hf
Shape Rolling
Ring Rolling
Thread Rolling
Figure 13.15 Thread-rolling
processes: (a) and (c) reciprocating
flat dies; (b) two-roller dies.
Threaded fasteners, such as bolts, are
made economically by these
processes, at high rates of production.
Tube Rolling
Figure 13.18
Schematic illustration
of various tube-rolling
processes: (a) with
fixed mandrel; (b)
with moving mandrel;
(c) without mandrel;
and (d) pilger rolling
over a mandrel and a
pair of shaped rolls.
Tube diameters and
thicknesses can also
be changed by other
processes, such as
drawing, extrusion,
and spinning.