5501ICBTAE
Automotive Materials & Manufacturing Processes
Lecture 7-Manufacturing
Processes-II
Forming or Metalworking Processes
• ‘Volume or Bulk forming’ relates to the
forming or changing of shape in a 3-D
manner. Involves deforming (plastic
deformation) a material until it attains
the required shape.
Forming or Metalworking Processes
• Starting material provides the needed
volume which is converted to the required
shape or geometry through shifting or
dislocation of material from unwanted
locations to the required locations.
Temperature Concerns
• Cold Working:
Defines as the plastic deformation of metals
below the recrystallization temperature.
The deformation is usually performed at room
temperature, but mildly elevated temperatures may
be used to provide increased ductility and reduced
strength.
Strength, fatigue, and wear properties are all
improved through strain hardening
•Hot Working:
Defines as the plastic deformation of
metals at a temperature above the
recrystallization temperature.
At hot working temperatures, recrystallization
eliminates the effects of strain hardening, so
there is no significant increase in yield
strength or hardness or corresponding
decrease in ductility.
Types of Forming Processes
Metal Forming Processes
Metal Forming
Forging
• Forging is a 3-D process used to produce a near
shape. Here too the shape of the die cavity is
imparted to the product, but unlike in casting - in
liquid state, and moulding – fluidic or flowing state,
‘Forging’ is done at solid state.
• Types of Forging based on forming process: Open-
die, Closed-die and Flashed die
• Types of Forging based on temperature: Hot, Cold,
Warm and Open Die Forging
• Hammers, pressure dies and presses are used to
apply the loads.
(a) Hot Forging
Open die forging- work piece is
compressed between two flat
platens or dies, allowing the metal
to flow without any restriction in
the sideward direction relative to
the die surfaces
Closed die forging- There is some
extra deformed material outside
the die impression which is called
as flash
Flashed die forging- work piece is
fully restricted within the die and no
flash is produced.
Applications
✓Wrenches
✓automotive crankshafts
✓piston connecting rods
✓Turbine & generator rotor
✓Chisel
✓Bolts
✓Hand tools
✓Ship building in various structure works
Rolling
• If a material is squeezed between two plates (ie.Ϭz
only) it will yield and deform in Ϭx and Ϭy dirctions.
Instead of plates if we use two rollers to squeeze
the material (between them) by rolling action then
too the material will deform.
• This is called Rolling.
• Rolling operations reduce the thickness or change
the cross section of a material through
compressive forces exerted by rolls.
• As in Forging, if the rolling is carried out below
re-crystallization temperature it is termed ‘Cold
rolling’, while above that is termed ‘Hot
rolling’. While materials of low flow stresses are
amenable to cold rolling, those with high flow
stresses are heated before rolling to reduce the
required forces.
• Steel is usually hot rolled while Aluminium, Tin
and similar materials are Cold rolled.
• Thick starting stock can be rolled into blooms,
billets, or slabs
Extrusion
• In the extrusion process, metal is compressed and
forced to flow through a suitably shaped die to
form a product with reduced but constant cross
section.
• Either hot or cold, hot extrusion is commonly
employed for many metals to reduce the forces
required, eliminate cold-working effects, and
reduce directional properties
• Aluminum, magnesium, copper, lead, and alloys of
these metals are commonly extruded, taking
advantage of the relatively low yield strengths and
low hot-working temperature
Applications
Electrical wires, bars and tubes
Collapsible tubes, gear blanks, aluminum cans,
cylinders are some of the items produced by cold
extrusion
Drawing (Wire/Rod/Tube)
• In extrusion, material is subjected to compressive forces.
Instead the required difference in principal stresses may be
obtained by subjecting one side (or an end) to a tensile
force.
• Thus if the material, say in the form of a rod, is pulled
through a ‘Die’ its diameter can be reduced. This is one of
the basic processes used to make wires.
• If a hollow section, instead of a solid section, is drawn
through a die aperture of a lower cross-section the product
so obtained will be a tube or a pipe. This process can be
used also to reduce the cross-section of pipes and tubes and
often a centre mandrel may be required to control the wall
thickness and/or internal diameter.
Wire, rod and tube drawing operations reduce the cross
section of a material by pulling it through a die
Wire drawing
Rod/bar drawing
Tube drawing
Sheet Metalworking Processes
• This differs from Volume forming in that the raw
materials used are in the form of sheets and not
billets, bar stocks or sections.
• Stress systems applied are 2-D compared to 3-D in
volume forming processes.
• Sheets can be formed into products by Blanking &
piercing, Bending, Drawing, Spinning, Shear & Flow
forming, Stretch forming and Explosive forming etc.
Blanking & piercing
• BLANKING & PIERCING which are basically shearing
operations carried out using ‘Die & Punch’ sets, find very
wide applications in industry.
Cup or Sheet drawing
• This is basically a process used to produce a cup
shape from a sheet. It is divided in to ‘Deep
drawing’ and ‘Shallow drawing’ based on the depth
of drawing. Naturally deep drawing involves higher
stresses and is complicated than shallow drawing.
• Cross-section of the drawn cup may be circular or
otherwise. Stresses involved in cup drawing
includes radial tensile and bending, as well as
tangential compressive
Spinning
• SPINNING is a process where deformation is obtained by
application of force on a work piece that is being rotated. At
any moment the forces applied and thus deformation is on a
single point. Therefore, forces involved are much less than
with cup drawing. Deformation takes place gradually and in
a spiral manner.
• As this involves revolving of the product around its axis, the
products are limited to axi-symmetric items.
• Aluminium, copper, brass, mild steel, and even stainless
steel find wide application with this process. Many kitchen
utensils, pots and pans, kettle bodies etc. are made with this
process.
Powder Metallurgy
• A process by which fine powdered materials are
blended, pressed into a desired shape (compacted),
and then heated (sintered) in a controlled
atmosphere to bond the contacting surfaces of the
particles and establish desired properties.
• The process, commonly designated for the mass
production of small, intricate parts of high
precision, often eliminating the need for additional
machining or finishing.
Powder Metallurgy
• Performed at temperature below the melting point
of the metal.
• The properties of powder metallurgy products are
highly dependent on the characteristics of the
starting powders.
• Some important properties and characteristics
include chemistry and purity, particle size, size
distribution, particle shape, and the surface texture
of the particles.
Joining & Assembly
• Once the Components or Parts are acquired or
made, they have to be assembled or jointed to
make the sub-assembly or final product / item
• Example:
Bicycle: Frame, Front & Rear wheel assemblies, Seat,
Pedal and Drive assembly.
Sub-assemblies : Wheel Assembly → Rim, Spokes, Hub,
Hub axle, Bearings, Tyre, Tube, Valve etc.
Types of Assembly processes
➢Mechanical
• Nails, Screws, Bolts and Nuts, Rivets, Clips (elastic),
Joints with some degrees of freedom.
➢Metallurgical
A metallurgical bond is where molecules
migrate from each other and forms a bonded
layer where molecules from each other are
mixed, bonded and cannot be distinguished.
For such bonding the two materials should
either be similar or with high affinity.
(a) Soldering
(b) Brazing
(c) Welding
Metallurgical joint processes
• Welding - Used only for similar materials (or
with high affinity). Usually brought to molten
state, or high temperature with application
of pressure
• Brazing - Materials dis-similar or with low
affinity. A third material having affinity to
both materials being joined is introduced in a
molten state.
• Soldering - Similar to brazing but with third
material of relatively low melting point.
➢Adhesive Bond
• Water based:
dissolved in water. Once applied water evaporates
off and the adhesive bonds the components. Very
often reversible. Ex. Gum, starch, Chemifix etc.
• Solvent based:
Dissolved in a solvent, often petroleum based.
Usually water proof. Solvent evaporates off
causing bonding. Ex. Rubber solutions, PVC
solvent cements etc.
• Epoxy based:
Usually two components: Resin and Hardener.
Nonreversible chemical reaction. Many different
compositions to suit various applications. Usually
water resistant and hard (rigid).
Additive Manufacturing
• In Additive manufacturing, a model is initially
generated using 3D computer aided design system.
Can be fabricated directly without the need for
process planning.
• It is a layer based automated fabrication process for
making scaled 3D physical objects directly from 3D
CAD data without using part depending tools.
• Called “3D Printing”
Additive Manufacturing processes
• Stereolithography: Builds epoxy parts one layer at a
time by tracing a laser beam on the surface of a vat
of liquid photopolymer. The material solidifies
wherever the laser beam strikes the surface of the
liquid.
• Laser Sintering: A thermoplastic powder is spread
by a roller over the surface of the part bed. The
piston in the cylinder moves down one object layer
thickness to accommodate each new layer of
powder
• Fused Deposition: A plastic filament is unwound
from a coil and supplies material to an extrusion
nozzle. The nozzle is heated to melt the material.
….THNAK YOU….
