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    Hammer Forging Two Connecting Rods : (A) (B) (C) (D) (E) (F) (G) (H)

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    eldhopaul19894886
    The document describes the hammer forging process used to create two connecting rods. It involves (a) using a bar stock, (b) fullering, (c) rolling, (d) blocking, (e) finishing, (f) trimming, with (g) flash removed using (h) forging dies.

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    Hammer Forging Two Connecting Rods : (A) (B) (C) (D) (E) (F) (G) (H)

    Uploaded by

    eldhopaul19894886
    21 views18 pages
    The document describes the hammer forging process used to create two connecting rods. It involves (a) using a bar stock, (b) fullering, (c) rolling, (d) blocking, (e) finishing, (f) trimming, with (g) flash removed using (h) forging dies.

    Original Title

    metal forming

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    The document describes the hammer forging process used to create two connecting rods. It involves (a) using a bar stock, (b) fullering, (c) rolling, (d) blocking, (e) finishing, (f) trimming, with (g) flash removed using (h) forging dies.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    21 views18 pages

    Hammer Forging Two Connecting Rods : (A) (B) (C) (D) (E) (F) (G) (H)

    Uploaded by

    eldhopaul19894886
    The document describes the hammer forging process used to create two connecting rods. It involves (a) using a bar stock, (b) fullering, (c) rolling, (d) blocking, (e) finishing, (f) trimming, with (g) flash removed using (h) forging dies.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 18

    (a) (b) (c) (d) (e) (f) (g) (h)

    Hammer forging two connecting rods; (a) bar stock;


    after (b) fullering, (c) “rolling”, (d) blocking, (e) finishing,
    (f) trimming; (g) the flash; (h) the forging dies.

    4
    Metal Forming Processes

    Sheet Metal-working: Bulk Deformation:


     Also called “Press-working”.  Compressive deformation force.

     Cold working processes.  Significant deformations.

     Use set of punch and die.  Massive shape changes.

     Performed on metal sheets, strips  Starting work shapes include billets


    and coils. and rectangular bars.

     Surface area / volume is large.  Surface area / volume is small.

    5
    Bulk Deformation Processes
    Forging: The work-piece is compressed between two
    opposing dies so that the die shapes are imparted to work.
    It is traditionally hot working process however many types
    of forging are performed cold.

    8
    Bulk Deformation Processes

    Extrusion: A compressive deformation process in which


    the work metal is forced to flow through a die opening to
    produce a desired cross-sectional shape.

    9
    Bulk Deformation Processes

    Drawing: The work metal is being pulled through a die


    opening to reduce the diameter of a wire or a bar. See Fig.
    Wire Drawing.

    10
    Examples of Precision
    Cold Forged Products

    11
    Precision Hot Forging of Complex
    Shapes

    12
    Precision Hot Forging of Complex
    Shapes

    13
    Sheet Metalworking Processes

    Bending: It involves straining of metal sheet or plate to take


    an angle along a (usually) straight axis.

    14
    Sheet Metalworking Processes
    Drawing: (Cup or deep drawing) Forming of a flat metal
    sheet into a hollow or concave shape, such as cup, by
    stretching the metal. A blank holder is used to hold down
    the blank while the punch pushes into the sheet metal.

    15
    16
    Sheet Metalworking Processes
    Shearing: It involves cutting rather than forming of a
    metal. A shearing operation cuts the work using a punch
    and die.

    17
    Importance of Metal Forming in
    Manufacturing Engineering

    • Net Shape or Close to Net Shape


    • High Production Rate
    • High Profit Margin
    • Low Scrap Rate
    • Improving Material Properties

    18
    Applications and Products of Metal
    forming in Macro Scale
    • Automotive
    • Aerospace
    • Appliance
    • Cookware

    19
    Current Issues of Metal Forming Industry

    • Lack of Experienced Metal Forming Engineer


    • Short Product Life Cycle
    • New Metallic Materials
    • Developing New Hybrid Process
    • High Accuracy and Small Feature Products

    20
    Skills Needed for Metal Forming
    Engineering
    • Mechanics
    • Material Science
    • Manufacturing Process
    • Design and Control
    • Machinery
    • Computer Skills
    • FEA

    21
    Students Need

    • To know the current and future needs of


    metal forming industry.

    • To be taught on a series of classes to meet


    challenges of current and future metal
    forming industry.

    22
    Homework
    • Is metal forming the most cost effective
    manufacturing process?
    • Why metal forming is the best process for
    mass production?
    • According to your imagination, what is the
    best process to make beverage can?

    23

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