Syllabus covered in this notes: Smithy and Forging (half part of UNIT-II): Basic operation e.g. upsetting, fullering, flattening, drawing and swaging: tools and appliances: drop forging, press forg...
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- lower maintenance Mechanical Press: - electric powered clutch engaged flywheel - stroke is applied by eccentric shaft - force depends on stroke position - may be used by less skilled operators Screw Press: - force transmitted through a vertical screw - powered by electric motor with fly wheel - energy limited (slows flywheel as press closes) Gravity Drop Hammers: - drop forging - converts potential energy to kinetic energy - energy limited - high speeds Power Drop Hammers: - converts potential energy to kinetic energy - down stroke is accelerated by steam, air, or hydraulic pressure Counter Blow Hammers: - uses two hammers that approach part simultaneously Selection of Forging Machine depends upon: - force and energy requirements - material to be forged (soft material use press…hard materials use hammers) - size, shape and complexity of forging - strength of the workpiece material - sensitivity of material to rate of deformation - production rate - dimensional accuracy - maintenance - operating skill level required - noise level - cost
Extrusion: A bulk forming process where a metal billet is squeezed through a metal die of constant cross sectional shape. There are two distinct forms of the extrusion process used: Hot Extrusion and Cold Extrusion
Hot Extrusion: used to produce long, extended products with a wide variety of constant cross sectional shapes. -- uses raw material at higher temperatures -- pressure or force is usually applied horizontally. -- usually produces parts up to 25 ft long (but in situations can be up to 100 ft) -- product is then cut into desired lengths and ends are trimmed -- can produce hollow shapes using special dies or insets -- cost can be competitive with roll forming -- moderate to high die and equipment cost -- low to moderate labor cost -- low to moderate operator skill -- commonly used for aluminum, copper, steel, magnesium, and lead. -- typical products include: railings, tubes, structural shapes, frame materials.
Table 1: Hot Extrusion Temperature Ranges for Various Metals Metal ºC Lead 200-250 Aluminum and Aluminum alloys 375-475 Copper and Copper alloys 650-975 Steels 875-1300 Refractory metals 975-2200 Extrusion Process: A round heated billet (raw material ) is placed in the extrusion chamber and a hydraulic ram is used to force the heated billet through the smaller die opening. As the material is forced through the opening, it takes on the constant cross sectional shape of the opening.
Softer materials such as lead, aluminum, and copper may be extruded without use of lubricants. Harder materials like steel require glass or ceramic lubricants to reduce friction along the sides of the chamber and to reduce the forces on the die.
Many manufacturers also advertise that they will custom make just about any shape you want, but at a higher cost than custom shapes. The shapes shown below are the cores offered by one extrusion manufacturer.
