IE 204 Manufacturing Processes

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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
FORMING AND SHAPING PROCESSES AND EQUIPMENT
Atilim University / Dept. of Industrial
Engineering
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CONTENTS
IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• Rolling
• Forging
• Extrusion and drawing
• Sheet-metal forming
• Powder Metallurgy
• Forming and shaping plastics and composites
  Rapid Prototyping
• Forming and shaping ceramics and glass

Atilim University / Dept. of Industrial
Engineering
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ROLLING
IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• Flat rolling
• Shape rolling

• Rolling is the process of
• reducing the thickess or
• changing the cross-section
• of a long workpiece by
• compressive forces applied
• through a set of rolls

Atilim University / Dept. of Industrial
Engineering
4
Flat Rolling
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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Shape Rolling
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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Applications
IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• Straight and long structural shapes
• Solid bars with various cross sections
• Channels
• I-beams
• Railroad rails

Atilim University / Dept. of Industrial
Engineering
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Production of Seamless Tubes and Pipes
IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• Rotary Tube Piercing (The Mannesmann Process)
• Hot-working process
• Radial compressive forces ? tensile stress at the
  center of the bar
• Cyclic compressive stresses ? cavity formation
• Diameter of tubes and pipes are reduced by tube
  rolling

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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Forging
IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• Press or forging hammer
• Discrete parts (bolts and
• rivets, connecting rods, shafts for turbines,
  gears,hand tools, structural components for
  machinery)
• Cold forging (at room temperature)
• Warm or hot forging (at elevated temperatures

• Forging is the name for
• processes whereby the
• workpiece is shaped by
• compressive forces applied
• through various dies and
• tools

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Open-die forging
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Impression-die and Closed-die Forging
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Related forging operations - Heading
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Piercing
Atilim University / Dept. of Industrial
Engineering
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Die Materials
IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• General requirements for die materials
• Strength and toughness at elevated temperatures
• Herdenability and ability to harden uniformly
• Mechanical and thermal shock resistance
• Wear resistance (abrasive wear resistance)
• Common die materials tool and die steels
  containing chromium, nickel, molybdenum and
  vanadium

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Economics of Forging
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering