Hot Working Process

Deformation: Hot-Working Process
Department of Industrial Engineering Universitas Indonesia

Powerpoint Templates Page 1
Classification of Deformation
Sequence of process: a. Primary b. Secondary Size and shape of work piece a. Bulk deformation process b. Sheet forming operations
Powerpoint Templates
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Some of Hot-Working Process

1. 2. 3. 4. 5. 6. Rolling Forging Extrusion Hot Drawing Pipe Welding Piercing
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1 Rolling
the first process that is used to convert material into finished wrought product
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Slab, Bloom, Billet

1. Slab Rectangular solid where the width is greater than twice thickness Can be further rolled to produce plate, sheet, and strip 2. Bloom Has a square or rectangular cross section with a thickness greater than 15 cm and a width < twice the thickness 3. Billet Has a square or rectangular cross section and smaller than bloom Produced by rolling or extrusion Powerpoint Templates
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Basic Rolling Process
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Rolling Mill Configurations
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2 Forging
Forging is term applied to a family of processes where deformation is induced by localized compressive forces. The equipment can be manual or power hammers, presses, or special forging machines. The term forging usually implies hot forging done above the recrystaIlization temperature.
Forging Material
The forging material may be Drawn out to increase its length and decrease its cross section, Upset to decrease the length and increase the cross section, Squeezed in closed impression dies to produce multidirectional flow.
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FORGING Common forging processes include:

Open-die drop-hammer forging Impression-die drop forging Press forging Upset forging Automatic hot forging Roll forging Swaging
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2aOpen Die Drop Hammer Forging
Blacksmiths use this process to reduce the thickness of bars by hammering the part on an anvil. Reduction in thickness is accompanied by barreling, as in Fig. 14.3c. (b) Reducing the diameter of a bar by open-die forging; note the movements of the dies and the workpiece. (c) The thickness of a ring being reduced by open-die forging.
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2b
Impression-Die Forging
(a) through (c) Stages in impression-die forging of a solid round billet. Note the formation of flash, which is excess metal that is subsequently trimmed off (d) Standard terminology for various features of a forging die.
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Required when larger pieces or thicker products must be formed. Deformation is analyzed in terms of forces or pressures. Produce a more uniform deformation and flow. Problems can arise because of longer time of contact between the dies and work-piece. Heated dies are generally used to: Reduce heat loss
Promote surface flow Enable production of finer details and closer tolerances Powerpoint Templates Page 14
2c Press Forging
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Upset-forging involves increasing diameter of material by compressing its length

It is the most widely used of all forging processes. Parts can be upset forged both hot and cold on special high- speed machines
2d Upset Forging
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2e Automatic Hot Forging

Highly automated upset equipment in which milllength steel bars (typically, 24 ft long) are fed into one end at room temperature and hot-forged products emerge from the other end at rates of up to 180 parts per minute( i.e. 86,400 parts per 8-hour shift).
These parts can be solid or hollow, round or symmetrical, up to 12 Ib (6 kg) in weight, and up to 7 in. (180 mm) in diameter. Small parts can be produced at up to 180 parts per minute, with rates for larger pieces on the order of 90 parts per minute
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2f
Roll Forging
the bar is progressively shaped as it is rolled out.
When the bar encounters a stop, the rolls rotate, and
The piece can be reinserted between the next set of grooves and the process repeated to produce the
desired size and shape.
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2g
Swaging
Schematic illustration of the rotary-swaging process. (b) Forming internal profiles on a tubular workpiece by swaging. (c) A die-closing swaging machine showing forming of a stepped shaft. (d) Typical parts made by swaging. Source: Courtesy of J. Richard Industries.
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3 Extrusion
In the extrusion process, metal is compressed and forced to flow through a suitably shaped die to form a product with reduced but constant cross section. Extrusion may be performed either hot or cold, hot extrusion is commonly employed for many metals to reduce the forces required.
Extrusion process is toothpaste out of a tube.

like
squeezing
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EXTRUSION
Lead, copper, aluminum, magnesium, and alloys of these metals are commonly extruded, because of relatively low yield strengths and low hot-working temperatures.
Steels, stainless steels, and nickel-based alloys are far more difficult to extrude.
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EXTRUSION
Almost any cross-sectional shape can be extruded from nonferrous metals..
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Extrusions and Products Made from Extrusions
Extrusions and examples of products made by sectioning off extrusions. Source: Courtesy of Kaiser Aluminum.
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Types of Extrusion
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4 Hot Drawing of Sheet and Plate

Drawing is a plastic deformation process in which a flat sheet or plate is formed into a recessed, three-dimensional part with a depth more than several times the thickness of the metal. As a punch descends into a mating die (or the die moves upward over a mating punch), the metal assumes the desired configuration. Hot drawing is used for forming relatively thick-walled parts of simple geometries, usually cylindrical. Because the material is hot, there is often considerable thinning as it passes through the dies. Powerpoint Templates
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5 PIPE WELDING
Large quantities of steel pipe are made by two processes that use hot forming of steel strip coupled with deformation-induced welding of its free edges.
Both of these processes, utilize steel in the form of skelp-long strips with specified width, thickness and edge configuration.
Because the skelp has been hot rolled previously and welding process produces further compressive working and recrystallization, pipe welded by these processes tends to be very uniform in quality.
PIPE WELDING
Butt-Welded Pipe In the butt-welding process for making pipe, steel skelp is heated to a specified hotworking temperature by passing it through a furnace. Upon exiting the furnace, it is pulled through forming rolls that shape it into a cylinder and bring the free ends into contact. The pressure exerted between the edges of the skelp is sufficient to upset the metal and produce a welded seam.
PIPEWELDING
Lap-Welded Pipe
Lap-welding process for making pipe differs from butt-welding technique in that skelp now has beveled edges and the rolls form the weld by forcing lapped edges down against a supported mandrel. This process is used primarily for larger sizes of pipe, from about 2 in. (50 mm) to 14 in. (400 mm) in diameter. Because product is driven over a supported mandrel, product length is limited to about 20 to 25 feet.
Thick-walled seamless tubing can be made by rotary piercing,
PIERCING
A heated billet is fed longitudinally into the gap between two large, convex-tapered rolls. These rolls are powered to rotate in the same direction, but axes of rolls are offset from axis of billet by about 6, one to right and the other to left.
PIERCING
As billet is caught by rolls, it is simultaneously rotated and driven forward. The reduced clearance between rolls forces billet to deform into a rotating ellipse. Rotation of the elliptical section causes the metal to shear about the major axis. A crack tends to form down the center axis of billet, and cracked billet is then forced over a pointed mandrel that enlarges and shapes the opening to form a seamless tube. Powerpoint Templates Page 36
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Hot Working Process

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Deformation: Hot-Working Process

Department of Industrial Engineering Universitas Indonesia

Some of Hot-Working Process

Slab, Bloom, Billet

Basic Rolling Process

Rolling Mill Configurations

FORGING Common forging processes include:

2aOpen Die Drop Hammer Forging

Upset-forging involves increasing diameter of material by compressing its length

2e Automatic Hot Forging

When the bar encounters a stop, the rolls rotate, and

desired size and shape.

Extrusion process is toothpaste out of a tube.

Almost any cross-sectional shape can be extruded from nonferrous metals..

Extrusions and Products Made from Extrusions

4 Hot Drawing of Sheet and Plate

Thick-walled seamless tubing can be made by rotary piercing,

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