8/11/2008

SME2713 ManufacturingProcess

4.1Introduction
1. 2. 3. 4. 5. 6. 7. 8. Classificationofmetalformingprocesses Definition Plasticdeformation Competitivecharacteristics Hotandcoldworking Recrystallization Strainhardening Processvariables
AssocProfZainalAbidinAhmad 2

METALFORMING 1
(Introduction)

AssocProfZainal Abidin Ahmad UTM,Skudai

11August2008

FormingProcesses
Sheet Sheet metal forming Vacuum forming Blow moulding Superplastic forming Bulk Forging Rolling Extrusion Drawing Powder Slip csting Pressing & sintering Isostatic pressing

Metal
11August2008

Polymer

Metal &Polymer

Ceramic

Ceramic & Metal

3 11August2008 AssocProfZainalAbidinAhmad 4

AssocProfZainalAbidinAhmad

8/11/2008

Primary working

BulkMetalForming

Rolling

Forging

Extrusion
11August2008 AssocProfZainalAbidinAhmad 5 11August2008 AssocProfZainalAbidinAhmad

Drawing
6

SheetMetalworking

2.MetalFormingDefinition
Agroupofmanufacturingprocessesinwhichthe materialisshapedtoacertaingeometrybyapplying externalforceslargeenoughtocauseapermanent deformation.Thedeformedmaterialexperienced plasticdeformation,i.e.itwillnotreturntoits originalshapeaftertheforcesarereleased. Theexternalforcescanbeintheformof compression,tension,torsion,shearing,bending, drawingoracombinationofthevariousforces.

11August2008

AssocProfZainalAbidinAhmad

11August2008

AssocProfZainalAbidinAhmad

8/11/2008

Varioustypesandcombinationofforces
Stresses in the form of compression, tension, shear and others

11August2008

AssocProfZainalAbidinAhmad

11August2008

AssocProfZainalAbidinAhmad

10

3.PlasticDeformation
ElasticDeformation If a metal deformed b af by force return t t to it its original i i l dimensions when the force is removed; the metal undergo elastic deformation

Plastic deformation (metals) Permanent deformation of metals due to the movement of dislocations on slip system.
11August2008 AssocProfZainalAbidinAhmad 11 11August2008 AssocProfZainalAbidinAhmad 12

8/11/2008

1. Initial

2. Small load
bonds stretch

3. Unload

1. Initial

return to initial

2. Small load bonds stretch & planes l shear

elastic + plastic

3. Unload
planes still sheared plastic

Elastic means reversible!

LinearLinear elastic Non-Linearelastic

F
linear elastic linear elastic

11August2008 AssocProfZainalAbidinAhmad

Plastic means permanent!

11August2008

13

AssocProfZainalAbidinAhmad

plastic

3 14

4.CompetitiveCharacteristics
Massconservation materialformedinto differentshapeswithoutchangingits volume,orminimumvolumechanges, therebylittlewasteorscrap. Bettermaterialproperties grain structureorfibre Veryfastproduction
11August2008 AssocProfZainalAbidinAhmad 15 11 August 2008 Assoc Prof Zainal Abidin Ahmad 16

8/11/2008

Comparisonofmicrostructure

CASTING Poor microstructure with high porosity Manufacture of a spark plug body : (left) by machining from hexagonal bar stock; (right) by cold forming. Note the reduction in waste
11August2008 AssocProfZainalAbidinAhmad 17 11August2008

MACHINING Grain structure being cut through

FORMING Fibrous g grain structure giving good mechanical properties

Mechanical properties improving

AssocProfZainalAbidinAhmad 18

Grain structure or fiber of machined vs rolled component

Parts produced within seconds

11August2008

AssocProfZainalAbidinAhmad

19

11August2008

AssocProfZainalAbidinAhmad

20

8/11/2008

WhataboutDisadvantages?
Pleasestateafewdisadvantagesascompared with ithother th manufacturing f t i processes

5.HotandColdWorking

11August2008

AssocProfZainalAbidinAhmad

21

11August2008

AssocProfZainalAbidinAhmad

22

HotWorking

11August2008

AssocProfZainalAbidinAhmad

23

11August2008

AssocProfZainalAbidinAhmad

24

8/11/2008

ColdWorking

TemperatureeffectonMetalWorking
Melting temperature Hot working Recrystalisation range Warm working g Cold working Ambient temperature 700 500 200 20
26

Steel 1500 0C

11August2008

AssocProfZainalAbidinAhmad

25

11August2008

AssocProfZainalAbidinAhmad

TemperatureinMetalworking
Hotworking Deformationattemperature above b recrystallization t lli ti temperature t t typically t i ll between0.5Tm to0.75Tm
Pros
largerdeformationpossible lowerforcesandpower formingofroomtemperaturelowductilitymaterialis possible isotropicpropertiesresultedfromprocess noworkhardening
11August2008 AssocProfZainalAbidinAhmad 27

TemperatureinMetalworking
Warmworking temperaturebetweenroom temperatureandrecrystallization temperature,roughly hl about b 0.3 0 3Tm
Prosagainstcoldworking
Lowerforcesandpower moreintricateworkgeometriespossible need dfor f annealing li maybe b reduced/eliminated. d d/ li i t d

11August2008

AssocProfZainalAbidinAhmad

28

8/11/2008

TemperatureinMetalworking
Coldworking
Pros
betterdimensionalcontrolandaccuracy Finegrain bettersurfacefinish strainhardeningincreasesstrengthandhardness grainflowduringdeformationprovidesdirectional properties noheatingisneeded,easierhandling(lowoperating temperature

TemperatureinMetalworking
IsothermalForming preheatingthetoolsto th samet the temperature t asth thework kmetal. t l Thi This eliminatesthesurfacecoolingandthe resultingthermalgradientintheworkpart. Normallyappliestohighlyalloyedsteels, titaniumalloys y andhigh g temperature p nickel alloys.

Cons
higherforcesandpowerarerequired,therefore biggercapacitymachines ductilityandstrainhardeninglimitstheextentof forming AssocProfZainalAbidinAhmad

11August2008

29

11August2008

AssocProfZainalAbidinAhmad

30

6.Recrystallization
The process in which, at a certain temperature range, new strain-free grains are formed, replacing the older grains.

6.Recrystallization

11August2008

AssocProfZainalAbidinAhmad

31

11August2008

AssocProfZainalAbidinAhmad

32

8/11/2008

Propertiesofsteels(C10)after hotandcoldworking

7.StrainHardening
Berlakuapabilalogamdikerjakandalam keadaansejuk, sejuk dimanakekuatanlogam bertambahdanpadamasayangsama kekerasanmeningkat. Jugadinamakanpengerasankerja Kesanlangsung Kekerasandankekuatanmeningkat Wujudtegasantinggal/baki Kemuluranberkurang

11August2008

AssocProfZainalAbidinAhmad

33

11August2008

AssocProfZainalAbidinAhmad

34

8.ProcessVariables independent

11August2008 AssocProfZainalAbidinAhmad 35

Startingmaterial types Startingworkpiecegeometry Toolanddiegeometry Lubrication Startingtemperature Speedofoperation Amountofdeformation

AssocProfZainalAbidinAhmad 36

11August2008

8/11/2008

DependentVariables
Forceorpowerrequired Natureofmaterialflow Materialproperties Exittemperature Surfacefinish

Outcome
Experience Experiments Theory

11August2008

AssocProfZainalAbidinAhmad

37

11August2008

AssocProfZainalAbidinAhmad

38

11August2008

AssocProfZainalAbidinAhmad

39

10