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What are the main factors to consider when selecting a die or mold material for metal forming applications?
What are the main factors to consider when selecting a die or mold material for metal forming applications?
The main factors include the operations to be performed, workpiece material properties, production rate, machine type, cost per part, and material properties.
Why is it important to select the proper material for metal forming applications?
Why is it important to select the proper material for metal forming applications?
Selecting the proper material can improve workpiece quality, increase productivity, and reduce costs.
What are cemented carbides and why are they significant in tool and die materials?
What are cemented carbides and why are they significant in tool and die materials?
Cemented carbides are hard, wear-resistant materials made of carbide particles bonded by a soft metal; they are significant due to their durability and effectiveness in metal forming.
List two types of nonferrous materials mentioned in the context of tool and die design.
List two types of nonferrous materials mentioned in the context of tool and die design.
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What role does the design of the die or mold play in the selection of materials for metal forming?
What role does the design of the die or mold play in the selection of materials for metal forming?
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How do the properties of die or mold materials impact their performance in metalworking?
How do the properties of die or mold materials impact their performance in metalworking?
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What considerations regarding production rates and quantities should be made when selecting die materials?
What considerations regarding production rates and quantities should be made when selecting die materials?
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What is the significance of the current availability of die materials in manufacturing?
What is the significance of the current availability of die materials in manufacturing?
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Study Notes
Materials Engineering III
- Course instructor: Dr. Nariman Ezzat
- Subject: Nonferrous Tool and Die Materials
Chapter Overview
- Discusses nonferrous materials used in metal-forming processes.
- Explores the composition and physical properties of principal die design materials for metal forming.
- Focuses on nonferrous materials crucial for producing dies in metal forming.
Introduction
- A wide range of materials are available for tool and die designers.
- No single material suits all forming applications due to diverse conditions and requirements in various operations.
Selecting Proper Material
- Choosing the right material improves workpiece quality, increases productivity, and reduces costs.
Metal Forming Processes
- Categorized into sheet metalworking and bulk deformation.
- Sheet metalworking: Bending, shearing, deep or cup drawing (surface area/volume ratio is large)
- Bulk deformation: Rolling, forging, extrusion, wire and bar drawing (surface area/volume ratio is small)
Temperature Ranges
- Metal forming processes occur across three temperature ranges.
- Cold working: ≤ 0.3 Tm
- Warm working: 0.3 Tm - 0.5 Tm
- Hot working: 0.5 Tm - 0.75 Tm (where Tm = melting point of the metal)
Sheet Metal Forming Processes
- Bending: Strains sheet material to form a bend shape.
- Deep drawing: Creates a hollow or concave shape from a flat sheet.
- Shearing: Cuts sheets by shearing action.
Bulk Metal Forming Processes
- Rolling: Reduces the thickness of slabs or plates by compressing them between rollers.
- Forging: Compresses the workpiece between dies to shape it.
- Extrusion: Pushes the workpiece into a die opening to adopt its shape.
- Wire/rod drawing: Pulls the workpiece through a die opening to create a desired cross-section.
Factors Affecting Die/Mold Material Selection
- Operations: Severity, applied forces, temperatures, and lubricants used.
- Workpiece: Hardness, thickness, condition, and size.
- Production: Rate, quantity, accuracy, and finish requirements.
- Machine: Type and condition.
- Cost: Per part, manufacturing, heat treatment, and maintenance.
- Design: Of the die or mold.
- Accuracy and Rigidity: Of the setup.
- Life: Of the die or mold.
- Current availability: Of die/mold material.
- Material properties: Resistance to wear, heat, deformation, machinability, heat treatability, and grindability.
Nonferrous Materials Used in Metal Working
- Cemented carbides: Most common, hard, wear-resistant, and manufactured through powder metallurgy.
- Ceramics
- Ultra-hard Tool Materials
Cemented Carbides (More Detail)
- Belong to a class of hard, wear resistant materials using cemented hard metal particles.
- First developed in Germany in the early 1920s to replace expensive diamond dies in tungsten filament wire drawing.
- First made using tungsten carbide (WC) with a cobalt binder.
Cemented Carbide Manufacturing
- Powder metallurgy process with several controlled steps to obtain final properties, microstructure, and performance:
- Ore processing and tungsten carbide powder preparation
- Other carbide powder preparation
- Powder milling
- Compacting or consolidation
- Sintering
- Post-sintering forming
- The sintered product may be further ground, polished, and coated for specific applications.
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Description
This quiz covers the chapter on Nonferrous Tool and Die Materials from Materials Engineering III. It explores the various nonferrous materials used in metal-forming processes, including their composition and properties. Test your understanding of material selection and its impact on productivity and cost in die design.
