MATERIAL PROCESSING: “ALL THAT IS DONE TO CONVERT STAFF TO THINGS” FAMILY: 1. CONSOLIDATION: PUTS PIECES TOGETHER 2. MATERIAL REMOVAL: BEGINS WITH OVERSIZE PIECE AND REMOVE MATERIAL. / MACHINING/ METAL CUTTING

3. CASTING: EXPLOITS FLUIDITY OF METAL’S LIQUID STATE 4. DEFORMATION: EXPLOITS DUCTILITY OF METALS AND PRODUCE S THE DESIRED SHAPE BY PLASTICITY

FUNDAMENTALS: Overview of Metal Forming - Industrial importance - Cost effectiveness - Enhanced mechanical properties - Flexible operations - Higher productivity - Considerable material saving Material Behavior in Metal Forming - Applies stresses exceeding the yield strength of the metal - Subjecting the material to plastic deformation - Through tensile, compressive, shear, bending or combination Temperature in Metal Forming - Hot and Cold forming

CLASSIFICATION Bulk deformation refers to the use of raw materials for forming which have low surface area to volume ratio. In this method, the nature of force applied may be compressive, compressive and tensile, shear or a combination of these forces. Produces parts having large surface area to thickness ratio. In sheet metal forming thickness variations are not desirable. Sheet metal forming involves application of tensile or shear forces predominantly. Sheet metal operations are mostly carried out in presses – hydraulic or pneumatic.

FORGING Material shaped by localized compressive forces Manually or with power hammers, presses or special forging machines Hot and Cold Forging  Hot Forging Generally used to produce discrete parts Good strength and toughness; can be used reliably for highly stressed and critical applications. Typical forged parts include rivets, bolts, crane hooks, connecting rods, gears, turbine shafts, hand tools, railroads, and a variety of structural components used to manufacture machinery.

FORGING EQUIPMENTS & TOOLS HEATING DEVICE - Hearth: for hand forging operation - Furnace: for heavy forging OTHER FEATURES - Fuels: solid, liquid, gas, or, electric - Temperature: it should gain required plastic properties before deformation - Excessive temperature : burning - Insufficient temperature: cold hardening and cracks Low carbon steels: 1,250 to 1,300°C, Wrought iron: 1,290°C. Bronze and Brass: 600 to 930°C, Aluminum and Magnesium alloys 340 to 500°C.

FORGING EQUIPMENTS & TOOLS contd…. TONGS - holding work while doing a forging operation OTHER FEATURES - Flat tong - Straight lip fluted tong - Rivet or ring tongs - Gad tongs

FORGING EQUIPMENTS & TOOLS contd…. PUNCH - for making holes in metal part when it is at forging heat. RIVET HEADER - produces rivets heads on parts.

FORGING EQUIPMENTS & TOOLS contd…. CHIESEL - used for cutting metals and for nicking prior to breaking OTHER FEATURES - hot or cold - main difference between the two is in the edge

FORGING EQUIPMENTS & TOOLS contd…. SWAGE BLOCK - mainly used for heading, bending, squaring, sizing, and forming operations on forging jobs.

FORGING EQUIPMENTS & TOOLS contd…. ANVIL - acts as a support for blacksmith’s work during hammering OTHER FEATURES - body of the anvil is made of mild steel with a tool steel face welded on the body - the beak or horn used for bending curves - round (pritchel hole) used for bending rods of small diameter - square (hardie hole) is used for holding square shanks