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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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