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Metal Forming and Manufacturing Processes
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Metal Forming and Manufacturing Processes

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Questions and Answers

Which type of extrusion process is most commonly used in industries to manufacture long products of uniform cross-section?

  • Radial extrusion
  • Hydrostatic extrusion
  • Direct extrusion (correct)
  • Indirect extrusion

    • What is the main difference between direct and indirect extrusion processes?

  • Direction of the ram movement
  • Frictional forces between billet and container (correct)
  • Material flow direction
  • Type of die used

    • What is the purpose of the hydrostatic fluid in hydrostatic extrusion?

  • To apply pressure on the billet to extrude it through the die (correct)
  • To reduce friction between billet and container
  • To change the direction of the metal flow
  • To increase the temperature of the billet

    • What type of forging process is classified based on the direction of applied force?

    <p>Hammer/drop forging and press forging</p> Signup and view all the answers

    What is the main operation performed in upset forging?

    <p>Increasing the cross section area at the expense of length</p> Signup and view all the answers

    What is the purpose of open die forging?

    <p>For initial breakdown of the billet</p> Signup and view all the answers

    What is the primary advantage of metal forming over other manufacturing processes?

    <p>High precision in production of complex shapes with minimal material wastage</p> Signup and view all the answers

    How many types of bulk metal deformation processes are there?

    <p>Four</p> Signup and view all the answers

    What is the main difference between hot, cold, and warm extrusion and forging processes?

    <p>Working temperature linked to recrystallization temperature</p> Signup and view all the answers

    What is the advantage of cold forging and extrusion processes compared to hot and warm processes?

    <p>Geometrical accuracy, surface finish, and mechanical properties of the final component</p> Signup and view all the answers

    What is the primary classification of extrusion processes?

    <p>Forward, backward, radial, and impact</p> Signup and view all the answers

    What is the force required to obtain deformation in metal forming?

    <p>Greater than the yield strength of the material</p> Signup and view all the answers

    What is the primary reason for using high-grade alloy steels with coatings in dies?

    <p>To increase the wear resistance</p> Signup and view all the answers

    What type of die is used to extrude simple designs of hard and tough metal?

    <p>Flat faced die</p> Signup and view all the answers

    What is the primary advantage of metal spinning over stamping and deep drawing processes?

    <p>Lower capital investment</p> Signup and view all the answers

    What is the purpose of the roller in the metal spinning process?

    <p>To press the metal against the tool</p> Signup and view all the answers

    What type of parts are often produced using the metal spinning process?

    <p>Pots and pans, vases, lamp shades</p> Signup and view all the answers

    What is an advantage of metal spinning in terms of tooling and methods?

    <p>Quick and inexpensive adaptation to design changes</p> Signup and view all the answers

    What is the main characteristic of closed die forging?

    <p>The workpiece is compressed between two die halves with flash arrangement.</p> Signup and view all the answers

    What is the advantage of combined extrusion-forging process?

    <p>It reduces capital investment and produces near-net shape products.</p> Signup and view all the answers

    What is the role of aluminium and its alloys in combined extrusion-forging process?

    <p>They play a crucial role in cold CEF &amp; CE processes.</p> Signup and view all the answers

    What is the benefit of cold CEF process?

    <p>It avoids complex tooling.</p> Signup and view all the answers

    What is the significance of combined extrusion-forging process in modern industry?

    <p>It has higher productivity and decrease in material wastage.</p> Signup and view all the answers

    What are dies in conventional dies?

    <p>They are the replica of the profile which is to be extruded or forged.</p> Signup and view all the answers

    What is the primary difference between hot spinning and cold spinning?

    <p>Hot spinning involves heating the metal blank, while cold spinning does not.</p> Signup and view all the answers

    What is the purpose of the back-up support in hot spinning?

    <p>To prevent wrinkling at the outer edge of the metal blank.</p> Signup and view all the answers

    What is the main application of wire drawing?

    <p>Manufacturing electrical wiring and cables.</p> Signup and view all the answers

    What is the primary advantage of metal spinning over other manufacturing processes?

    <p>Low tooling costs and short lead times.</p> Signup and view all the answers

    What is the main difference between deep drawing and extrusion?

    <p>In deep drawing, the metal is pushed through the die, while in extrusion, the metal is pulled through the die.</p> Signup and view all the answers

    What is the primary purpose of tube drawing?

    <p>To decrease the diameter, improve surface finish, and improve dimensional accuracy.</p> Signup and view all the answers

    What is the primary advantage of metal forming over other manufacturing processes?

    <p>Minimal material wastage and better mechanical properties</p> Signup and view all the answers

    What is the main classification of metal forming processes?

    <p>Bulk metal working and sheet metal working processes</p> Signup and view all the answers

    What is the primary difference between hot and cold forging processes?

    <p>Temperature of the working material</p> Signup and view all the answers

    What is the advantage of cold extrusion over hot extrusion?

    <p>Better surface finish</p> Signup and view all the answers

    What is the characteristic of indirect extrusion?

    <p>Frictional force between billet and container interface is eliminated</p> Signup and view all the answers

    What type of components are commonly produced by radial extrusion?

    <p>Flange type components</p> Signup and view all the answers

    What is the primary application of impact extrusion?

    <p>Production of toothpaste tubes</p> Signup and view all the answers

    What is the force required for metal forming?

    <p>Higher than the yield strength of the material</p> Signup and view all the answers

    What is the benefit of metal forming in terms of material wastage?

    <p>Minimal material wastage</p> Signup and view all the answers

    What is the classification of metal forming based on the type of deformation?

    <p>Bulk metal working and sheet metal working</p> Signup and view all the answers

    Study Notes

    Conventional Manufacturing Processes

    • Metal forming has advantages over other manufacturing processes due to high precision, minimal material wastage, and better mechanical properties.
    • Metal forming is a process of plastically deforming a metal block to a desired geometry by applying a force higher than the yield strength of the material.

    Bulk Metal Working Processes

    • Classified into four types: rolling, forging, extrusion, and drawing.
    • Forging and extrusion are frequently used forming processes since the 18th century.

    Extrusion and Forging Processes

    • Can be carried out under three working temperatures: hot, cold, and warm linked to recrystalization temperature.
    • Cold forging and extrusion processes have more advantages compared to hot and warm processes with respect to geometrical accuracy, surface finish, and mechanical properties of the final component.

    Extrusion Processes

    • Classified into four types depending on the relative movement of the punch and extruded product:
      • Forward (Direct) extrusion: most common method used in industries to manufacture long products of uniform cross-section.
      • Backward (Indirect) extrusion: billet does not move relative to the container, eliminating frictional force between billet and container interface.
      • Radial (Lateral) extrusion: material flow perpendicularly to the direction of the punch movement.
      • Impact extrusion: similar to backward/indirect extrusion process, with a punch running down quickly on the blank to obtain a tubular section.

    Forging Processes

    • Classified into:
      • Upset forging: force applied parallel to the length direction to increase the cross-section at the expense of length.
      • Drawing out: force applied perpendicular to the length axis to decrease the cross-section area.
      • Open die forging: work is compressed between two flat dies, allowing metal to flow freely laterally.
      • Closed die or Impression die forging: work piece is compressed between two die halves to obtain a multidirectional unbroken grain flow.
      • Flashless forging: volume of the workpiece is equal to the volume of the die cavity, with no requirement of flash arrangement.

    Combined Extrusion Forging Processes

    • Combined forward and backward extrusion (CE): simultaneous backward and forward extrusion.
    • Combined extrusion-forging (CEF): both extrusion and forging take place simultaneously to obtain a complex shape.

    Dies

    • Types of dies:
      • Flat faced dies: most preferred in the industry due to its simple design and low cost.
      • Taper or conical dies: have an entrance angle for metal flow.
      • Curved dies: minimize friction loss and redundant work.

    Metal Spinning

    • A process of forming rotationally symmetrical hollow parts from circular blanks.
    • Used to produce cone-shaped, elliptical, or other concave or convex parts.
    • Metal spinning yields pots, pans, vases, lamp shades, musical-instrument parts, and trophies.

    Drawing

    • A process of cold forming a flat precut metal blank into a hollow vessel.
    • Various forms produced include cylindrical, box-shaped, and irregular shapes.
    • Used to produce cups, cans, pans, cylinders, domes, hemispheres, tubes, and hoppers.

    Wire Drawing

    • A metalworking process used to reduce the cross-section of a wire by pulling the wire through a single, or series of, drawing die(s).
    • Used to produce electrical wiring, cables, tension-loaded structural components, springs, and paper clips.

    Tube Drawing

    • A process similar to bar drawing, used to decrease the diameter, improve surface finish, and improve dimensional accuracy of tubes.

    • A mandrel may or may not be used depending on the specific process used.### Types of Extrusion

    • Direct extrusion: billet moves relative to the container

    • Indirect (Backward or Reverted) extrusion: billet does not move relative to the container, die fixed on a hollow ram pushes against the billet, eliminating frictional force between billet and container interface

    • Radial (Lateral) extrusion: material flow perpendicularly to the direction of the punch movement, requiring additional power to overcome friction at the die-billet interface, commonly used for production of flange type components

    • Impact extrusion: similar to indirect extrusion, punch runs down quickly on the blank, resulting in a tubular section, used to produce toothpaste tubes

    • Hydrostatic extrusion: billet is extruded through the die by the action of a hydrostatic liquid pressure medium, rather than direct application of load with a ram, allows for extrusion of brittle materials, can be done hot, warm, or cold

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    Learn about the importance of metal forming in manufacturing, its advantages, and applications in industries. Understand the process and its benefits over other conventional manufacturing techniques.

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