FORMING AND SHAPING PROCESSES Dr. Zühal ERDEN FORMING AND SHAPING PROCESSES AND EQUIPMENT Atılım University / Dept. of Industrial Engineering

CONTENTS Rolling Forging Extrusion and drawing Sheet-metal forming IE 204 Manufacturing Processes Dr. Zühal ERDEN CONTENTS Rolling Forging Extrusion and drawing Sheet-metal forming Powder Metallurgy Forming and shaping plastics and composites; Rapid Prototyping Forming and shaping ceramics and glass Atılım University / Dept. of Industrial Engineering

ROLLING Flat rolling Shape rolling IE 204 Manufacturing Processes Dr. Zühal ERDEN ROLLING Rolling is the process of reducing the thickess or changing the cross-section of a long workpiece by compressive forces applied through a set of rolls Flat rolling Shape rolling Atılım University / Dept. of Industrial Engineering

Flat Rolling IE 204 Manufacturing Processes Dr. Zühal ERDEN Atılım University / Dept. of Industrial Engineering

Shape Rolling IE 204 Manufacturing Processes Dr. Zühal ERDEN Atılım University / Dept. of Industrial Engineering

Straight and long structural shapes IE 204 Manufacturing Processes Dr. Zühal ERDEN Applications Straight and long structural shapes Solid bars with various cross sections Channels I-beams Railroad rails Atılım University / Dept. of Industrial Engineering

Production of Seamless Tubes and Pipes IE 204 Manufacturing Processes Dr. Zühal ERDEN Production of Seamless Tubes and Pipes Rotary Tube Piercing (The Mannesmann Process) Hot-working process Radial compressive forces  tensile stress at the center of the bar Cyclic compressive stresses  cavity formation Diameter of tubes and pipes are reduced by tube rolling Atılım University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes Dr. Zühal ERDEN Atılım University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes Dr. Zühal ERDEN Forging Press or forging hammer Discrete parts (bolts and rivets, connecting rods, shafts for turbines, gears,hand tools, structural components for machinery) Cold forging (at room temperature) Warm or hot forging (at elevated temperatures Forging is the name for processes whereby the workpiece is shaped by compressive forces applied through various dies and tools Atılım University / Dept. of Industrial Engineering

Open-die forging IE 204 Manufacturing Processes Dr. Zühal ERDEN Atılım University / Dept. of Industrial Engineering

Impression-die and Closed-die Forging IE 204 Manufacturing Processes Dr. Zühal ERDEN Impression-die and Closed-die Forging Atılım University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes Dr. Zühal ERDEN Atılım University / Dept. of Industrial Engineering

Related forging operations - Heading IE 204 Manufacturing Processes Dr. Zühal ERDEN Related forging operations - Heading Atılım University / Dept. of Industrial Engineering

Piercing IE 204 Manufacturing Processes Dr. Zühal ERDEN Atılım University / Dept. of Industrial Engineering

Die Materials General requirements for die materials: IE 204 Manufacturing Processes Dr. Zühal ERDEN Die Materials General requirements for die materials: Strength and toughness at elevated temperatures Herdenability and ability to harden uniformly Mechanical and thermal shock resistance Wear resistance (abrasive wear resistance) Common die materials: tool and die steels containing chromium, nickel, molybdenum and vanadium Atılım University / Dept. of Industrial Engineering

Economics of Forging IE 204 Manufacturing Processes Dr. Zühal ERDEN Atılım University / Dept. of Industrial Engineering

IE 204 Manufacturing Processes Dr. Zühal ERDEN Atılım University / Dept. of Industrial Engineering