Survey of Mechanical Working: A. Introduction

Unit 4
Survey of Mechanical Working
A. Introduction
This unit is proposed to deal with deformation which may be used to obtain intermediate or
final shapes in metal. Liquid metal may be cast to shape in molds, sprayed to form intermediate
or final shapes or made into powder which is pressed into shape and sintered to produce strong
components.
While each of these has a field of application, the overwhelming bulk of metal is shaped from
the simple cast ingot by a series of deformation processes. The applicability and development
of these processes is completely dependent on the plasticity of the solid metal. The study of
plasticity is concerned with the relationship between metal flow and applied stress. If this can
be determined, then the required shapes can be achieved by the application of calculated forces
in specified directions at controlled rates.
In practice the external load is applied by a tool and its shape controls the direction of
application necessary to achieve the desired flow. The type of tool can be used to classify the
different categories of deformation processes.
Common industrial processes fall into six categories – deep drawing or pressing, rolling,
forging, stretching, extrusion and wiredrawing. There are other working processes, e.g. roll
forging, spray forming, etc., but these are not yet of any great industrial significance.
B. Deep drawing and pressing

Deep drawing is an extension of pressing in that the metal blank is given a substantial third
dimension after flowing through a die. Simple pressing is carried out by loading a blank
between a punch and a die so as to indent the blank and give the product a measure of rigidity.
Can ends in food and beverage containers are the most widespread examples.
As will be seen later this process can only be carried out cold. Any attempt at hot drawing
results in the metal necking and failing.
C. Rolling
This is a process which reduces the thickness of the material passed between a pair of revolving rolls.
The rolls are generally cylindrical producing a flat product such as sheets or strip. They can also be
grooved or textured on the surface in order to change profile as well as emboss patterns.
This deformation process can be carried out either hot or cold. Hot working is very widely used
because it is possible to achieve rapid and cheap change of shape. Cold rolling is carried out for special
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reasons such as the production of good surface finish or special mechanical properties. More metal is
rolled than the total treated by all other processes.
This is an indirect compression process. Normally the only force or stress applied is the radial pressure
from the rolls. This deforms the metal and pulls it through the roll gap. The process can be compared to
compression or forging but differs in two respects in that compression take place between a pair of
platens at various inclinations to each other, and that the process is continuous.
Rolling is the most widely used deformation process and for the reason that there are so many versions
the process has its own classification. This can be according to the arrangement of the rolls in the mill
stand or according to the arrangement of the stands in sequence.
D. Forging
Forging was the first of the indirect compression-type process and is probably the oldest method
of metal forming. It involves the application of a compressive stress which exceeds the flow
stress of the metal. The stress can either applied quickly or slowly. The process can be carried out
hot or cold, choice of temperature being decided by such factors as whether ease and cheapness
of deformation, production of certain mechanical properties or surface finish is the overriding
factor.
There are two kinds of forging process, impact forging and press forging. In the former, the load
is applied by impact, and deformation takes place over a very short time. Press forging, on the
other hand, involves the gradual build up of pressure to cause the metal to yield. The time of
application is relatively long. Over 90% of forging processes are hot. Impact forging can be
further subdivided into three types.
E. Wire Drawing
Metal rod is pointed at one end and then drawn through the tapered orifice of a die. The rod
entering the die has a large diameter and leaves with a smaller diameter. In the early examples
of this process, short lengths were drawn by hand through a series of holes of diminishing size
in a cast-iron or forged steel draw plate. Modern installation, in which long lengths are drawn
continuously through a series of died by the use of a number of mechanically driven blocks,
can produce very large quantities of wire in long lengths at high speed, using very little
manpower. By using the appropriately shaped orifice it is possible to draw a variety of shapes
such as ovals, squares, hexagons, etc., by this process.
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F. Choose a, b, c, or d which best completes each item.
1. The rolls are generally cylindrical producing a flat product such as …………. .
a. sheet b. strip c. deformed metal d. both a and b
2. The study of plasticity is concerned with the relationship between …….. and …….. .
a. the controlled rates / metal flow b. metal flow / backing rolls
c. applied stress / rolling speed d. metal flow / applied stress
3. As indicated by the author, common industrial processes of deformation fall into ……..
categories.
a. five b. six c. four d. seven
4. The metal blank is given a substantial third dimension in deep-drawing process after flowing
through ……… .
a. a die b. spray-forming process c. six categories d. stretching process
5. As indicated by the passage, …………. is (are) not of any great industrial significance.
a. roll forging and spray forming b. extrusion c. stretching d. pressing
6. Deep drawing is ………….. process.
a. a direct compression b. an indirect compression
c. an indirect non-compression d. a direct non-compression
7. The rolling load can be minimized by making the roll ……….. as smooth as possible.
a. diagram b. angle c. surface d. design
8. The most important part of the wire drawing machine is the ……….. .
a. die b. diameters c. proportionality d. friction
9. Impact forging usually involves a mechanical …………. .
a. press b. microstructure c. macrostructure d. structure
10. The capacity for ……….. by ductility is the most important characteristic of metals.
a. demonstration b. dislocation c. deformation d. application
11. Rigidity is one of the most important features of gauge design. The word "rigidity" is the
synonym of …. .
a. flexibility b. stiffness c. elasticity d. plasticity
12. Toughness is defined as the work per unit volume required to ….. a material and is
commonly expressed as modulus of toughness.
a. fracture b. process c. harden d. strengthen
13. This is undoubtedly the oldest type of forging, but it is now relatively …… .
a. common b. advanced c. uncommon d. prevalent
14. In practice the …. load is applied by a tool and its …. controls the direction of application.
a. internal/surface b. external/shape c. internal/shape d. external/surface
15. Increasing the ram speed produces ……. In extrusion pressure.
a. a decrease b. a drop c. an increase d. no change
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G. Technical Terms
Match the words in column I with their appropriate equivaent in column II.
1. elastic ( ) a. a twisting action applied to a shaft-like

or cylindrical member
b. permitting plastic deformation prior to
2. tensile ( )
eventual fracture
c. able to return immediately to the
3. necking ( ) original size and shape after being
stretched ; springy.
d. permanent deformation caused by
4. torsion ( )
application of an external force to a metal
below its recrystallization temperature
5. ductile ( ) e. pertaining to forces on a body that tend
to stretch, or elongate the body
f. reducing the cross-sectional area of
6. cold work ( )
metal in an area by stretching
H. Fill in the blanks with the following words.
floor efficiency friction toughness

brakes carbon-steel technology fundamentally
vehicle mechanical surfaces progressive
The movement of one solid surface over another is …………….. important to the
functioning of many kinds of mechanism, both artificial and natural. Tribology is the science
and ………… of interacting surfaces in relative motion.
In many instances, low ……… is desirable, for example hinges on doors demand a low
friction force. Work done in overcoming friction in bearing and other ………… components
of machines is dissipated as heat, and its reduction will lead to an overall increase in ……….
. But low friction is not necessarily beneficial in all cases. In ………… and clutches, friction
is essential; high friction is not similarly desirable between a …………… tire and the road
surface, just as it is between shoe and ………. for walking.
Whenever ………… move over each other, wear will occur; damage to one of both surfaces,
generally involving ……………. loss of material.
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Unit 4

Survey of Mechanical Working

B. Deep drawing and pressing

1. elastic ( ) a. a twisting action applied to a shaft-like

H. Fill in the blanks with the following words.

floor efficiency friction toughness

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