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Which type of extrusion process is most commonly used in industries to manufacture long products of uniform cross-section?
Which type of extrusion process is most commonly used in industries to manufacture long products of uniform cross-section?
What is the main difference between direct and indirect extrusion processes?
What is the main difference between direct and indirect extrusion processes?
What is the purpose of the hydrostatic fluid in hydrostatic extrusion?
What is the purpose of the hydrostatic fluid in hydrostatic extrusion?
What type of forging process is classified based on the direction of applied force?
What type of forging process is classified based on the direction of applied force?
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What is the main operation performed in upset forging?
What is the main operation performed in upset forging?
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What is the purpose of open die forging?
What is the purpose of open die forging?
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What is the primary advantage of metal forming over other manufacturing processes?
What is the primary advantage of metal forming over other manufacturing processes?
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How many types of bulk metal deformation processes are there?
How many types of bulk metal deformation processes are there?
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What is the main difference between hot, cold, and warm extrusion and forging processes?
What is the main difference between hot, cold, and warm extrusion and forging processes?
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What is the advantage of cold forging and extrusion processes compared to hot and warm processes?
What is the advantage of cold forging and extrusion processes compared to hot and warm processes?
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What is the primary classification of extrusion processes?
What is the primary classification of extrusion processes?
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What is the force required to obtain deformation in metal forming?
What is the force required to obtain deformation in metal forming?
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What is the primary reason for using high-grade alloy steels with coatings in dies?
What is the primary reason for using high-grade alloy steels with coatings in dies?
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What type of die is used to extrude simple designs of hard and tough metal?
What type of die is used to extrude simple designs of hard and tough metal?
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What is the primary advantage of metal spinning over stamping and deep drawing processes?
What is the primary advantage of metal spinning over stamping and deep drawing processes?
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What is the purpose of the roller in the metal spinning process?
What is the purpose of the roller in the metal spinning process?
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What type of parts are often produced using the metal spinning process?
What type of parts are often produced using the metal spinning process?
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What is an advantage of metal spinning in terms of tooling and methods?
What is an advantage of metal spinning in terms of tooling and methods?
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What is the main characteristic of closed die forging?
What is the main characteristic of closed die forging?
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What is the advantage of combined extrusion-forging process?
What is the advantage of combined extrusion-forging process?
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What is the role of aluminium and its alloys in combined extrusion-forging process?
What is the role of aluminium and its alloys in combined extrusion-forging process?
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What is the benefit of cold CEF process?
What is the benefit of cold CEF process?
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What is the significance of combined extrusion-forging process in modern industry?
What is the significance of combined extrusion-forging process in modern industry?
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What are dies in conventional dies?
What are dies in conventional dies?
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What is the primary difference between hot spinning and cold spinning?
What is the primary difference between hot spinning and cold spinning?
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What is the purpose of the back-up support in hot spinning?
What is the purpose of the back-up support in hot spinning?
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What is the main application of wire drawing?
What is the main application of wire drawing?
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What is the primary advantage of metal spinning over other manufacturing processes?
What is the primary advantage of metal spinning over other manufacturing processes?
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What is the main difference between deep drawing and extrusion?
What is the main difference between deep drawing and extrusion?
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What is the primary purpose of tube drawing?
What is the primary purpose of tube drawing?
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What is the primary advantage of metal forming over other manufacturing processes?
What is the primary advantage of metal forming over other manufacturing processes?
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What is the main classification of metal forming processes?
What is the main classification of metal forming processes?
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What is the primary difference between hot and cold forging processes?
What is the primary difference between hot and cold forging processes?
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What is the advantage of cold extrusion over hot extrusion?
What is the advantage of cold extrusion over hot extrusion?
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What is the characteristic of indirect extrusion?
What is the characteristic of indirect extrusion?
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What type of components are commonly produced by radial extrusion?
What type of components are commonly produced by radial extrusion?
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What is the primary application of impact extrusion?
What is the primary application of impact extrusion?
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What is the force required for metal forming?
What is the force required for metal forming?
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What is the benefit of metal forming in terms of material wastage?
What is the benefit of metal forming in terms of material wastage?
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What is the classification of metal forming based on the type of deformation?
What is the classification of metal forming based on the type of deformation?
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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
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A process similar to bar drawing, used to decrease the diameter, improve surface finish, and improve dimensional accuracy of tubes.
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A mandrel may or may not be used depending on the specific process used.### Types of Extrusion
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Direct extrusion: billet moves relative to the container
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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
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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
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Impact extrusion: similar to indirect extrusion, punch runs down quickly on the blank, resulting in a tubular section, used to produce toothpaste tubes
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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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Description
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.
