Manufacturing engineering - METAL FORMING

Introduction 5 lectures 24:24 Scope of the course preview In this lecture the complete syllabus of the course is discussed with a clear description of each metal forming processes as such rolling, forging, extrusion, drawing and sheet metal. What is metal forming preview Metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation; the workpiece is reshaped without adding or removing material, and its mass remains unchanged. Re-crystallization Recrystallization is a process by which deformed grains are replaced by a new set of defect-free grains that nucleate and grow until the original grains have been entirely consumed. Hot VS Cold working of metals A critical comparison between hot and cold working is made in this lecture. Flow stress Flow stress is defined as the instantaneous value of stress required to continue plastically deforming the material - to keep the metal flowing. Introduction 5 lectures 24:24 Scope of the course preview In this lecture the complete syllabus of the course is discussed with a clear description of each metal forming processes as such rolling, forging, extrusion, drawing and sheet metal. What is metal forming preview Metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation; the workpiece is reshaped without adding or removing material, and its mass remains unchanged. Re-crystallization Recrystallization is a process by which deformed grains are replaced by a new set of defect-free grains that nucleate and grow until the original grains have been entirely consumed. Hot VS Cold working of metals A critical comparison between hot and cold working is made in this lecture. Flow stress Flow stress is defined as the instantaneous value of stress required to continue plastically deforming the material - to keep the metal flowing. Scope of the course preview In this lecture the complete syllabus of the course is discussed with a clear description of each metal forming processes as such rolling, forging, extrusion, drawing and sheet metal. Scope of the course preview In this lecture the complete syllabus of the course is discussed with a clear description of each metal forming processes as such rolling, forging, extrusion, drawing and sheet metal. Scope of the course preview In this lecture the complete syllabus of the course is discussed with a clear description of each metal forming processes as such rolling, forging, extrusion, drawing and sheet metal. Scope of the course preview In this lecture the complete syllabus of the course is discussed with a clear description of each metal forming processes as such rolling, forging, extrusion, drawing and sheet metal. In this lecture the complete syllabus of the course is discussed with a clear description of each metal forming processes as such rolling, forging, extrusion, drawing and sheet metal. In this lecture the complete syllabus of the course is discussed with a clear description of each metal forming processes as such rolling, forging, extrusion, drawing and sheet metal. What is metal forming preview Metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation; the workpiece is reshaped without adding or removing material, and its mass remains unchanged. What is metal forming preview Metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation; the workpiece is reshaped without adding or removing material, and its mass remains unchanged. What is metal forming preview Metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation; the workpiece is reshaped without adding or removing material, and its mass remains unchanged. What is metal forming preview Metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation; the workpiece is reshaped without adding or removing material, and its mass remains unchanged.Metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation; the workpiece is reshaped without adding or removing material, and its mass remains unchanged.Metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation; the workpiece is reshaped without adding or removing material, and its mass remains unchanged. Re-crystallization Recrystallization is a process by which deformed grains are replaced by a new set of defect-free grains that nucleate and grow until the original grains have been entirely consumed. Re-crystallization Recrystallization is a process by which deformed grains are replaced by a new set of defect-free grains that nucleate and grow until the original grains have been entirely consumed. Re-crystallization Recrystallization is a process by which deformed grains are replaced by a new set of defect-free grains that nucleate and grow until the original grains have been entirely consumed. Re-crystallization Recrystallization is a process by which deformed grains are replaced by a new set of defect-free grains that nucleate and grow until the original grains have been entirely consumed. Recrystallization is a process by which deformed grains are replaced by a new set of defect-free grains that nucleate and grow until the original grains have been entirely consumed. Recrystallization is a process by which deformed grains are replaced by a new set of defect-free grains that nucleate and grow until the original grains have been entirely consumed. Hot VS Cold working of metals A critical comparison between hot and cold working is made in this lecture. Hot VS Cold working of metals A critical comparison between hot and cold working is made in this lecture. Hot VS Cold working of metals A critical comparison between hot and cold working is made in this lecture. Hot VS Cold working of metals A critical comparison between hot and cold working is made in this lecture. A critical comparison between hot and cold working is made in this lecture. A critical comparison between hot and cold working is made in this lecture. Flow stress Flow stress is defined as the instantaneous value of stress required to continue plastically deforming the material - to keep the metal flowing. Flow stress Flow stress is defined as the instantaneous value of stress required to continue plastically deforming the material - to keep the metal flowing. Flow stress Flow stress is defined as the instantaneous value of stress required to continue plastically deforming the material - to keep the metal flowing. Flow stress Flow stress is defined as the instantaneous value of stress required to continue plastically deforming the material - to keep the metal flowing. Flow stress is defined as the instantaneous value of stress required to continue plastically deforming the material - to keep the metal flowing. Flow stress is defined as the instantaneous value of stress required to continue plastically deforming the material - to keep the metal flowing. Rolling. 11 lectures 01:12:16 Terminology In this lecture you will understand about different terminologies of raw material (Such as billet,bloom,slab etc) used in rolling process. Rolling mechanism - Avoiding unbalanced forces The process of shaping metals into semi-finished or finished forms by passing between rollers is called rolling. Rolling is the most widely used metal forming process. It is employed to convert metal ingots to simple stock members like slabs, sheets, plates, beams, channels, angles, rods and strips etc. In rolling, the metal is plastically deformed by passing it between rollers rotating in opposite direction. The main objective of rolling is to decrease the thickness of the metal. Ordinarily, there is negligible increase in width, so that the decrease in thickness results in an increase in length.Rolling is done both hot and cold. It is accomplishes in rolling mills. A rolling mill is a complex machine having two or more working rollers, supporting rollers, roll stands, drive motor, reducing gear, flywheel, coupling gear etc. Rollers may be plain or grooved depends upon the shape of rolled product. The metal changes its shape gradually during the period in which it is in contact with the two rollers. PS - This lecture is the first part for understanding rolling mechanism in detail. Don't forget to see the second part in the next lecture. Rolling mechanism - Angle of bite & Deformation length The process of shaping metals into semi-finished or finished forms by passing between rollers is called rolling. Rolling is the most widely used metal forming process. It is employed to convert metal ingots to simple stock members like slabs, sheets, plates, beams, channels, angles, rods and strips etc. In rolling, the metal is plastically deformed by passing it between rollers rotating in opposite direction. The main objective of rolling is to decrease the thickness of the metal. Ordinarily, there is negligible increase in width, so that the decrease in thickness results in an increase in length.Rolling is done both hot and cold. It is accomplishes in rolling mills. A rolling mill is a complex machine having two or more working rollers, supporting rollers, roll stands, drive motor, reducing gear, flywheel, coupling gear etc. Rollers may be plain or grooved depends upon the shape of rolled product. The metal changes its shape gradually during the period in which it is in contact with the two rollers. PS - This lecture is the second part for understanding rolling mechanism in detail. Don't forget to see the first part in the previous lecture. Slip In materials science, slip is the large displacement of one part of a crystal relative to another part along crystallographic planes and directions. Slip occurs by the passage of dislocations on close packed planes which are planes containing the greatest number of atoms per area and in close-packed directions (most atoms per length). Maximum reduction For greater reduction, more frictional force is required, and because it is not available, the rolls start slipping over the strip. Thus it is that maximum possible reduction is achieved when the neutral point is at the exit, that is, when the exit velocity is equal to the circumferential roll velocity.All the concerned mathematical deductions are explained in this lecture. Force and power in rolling processes Mathematical deductions of rolling force and power is discussed in this lecture. Reducing Power & Force There is a need to reduce rolling force and power in order to get desired shape and size of the product. This is accomplished by several means as explained in this lecture. Types of rolling mills As per the requirement of the process and arrangement of the rolls, the rolling mill rolls can be divided into the following categories: 1.Two High Rolling MillsIt consists of two rollers, which rotate in the opposite direction for the desired movement of the workpiece. The workpiece is fed between the rollers, which apply a full force, and tends to deform a workpiece and convert it into the desired shape. If you want a robust and quality two high rolling mill, you can look for mill rolls manufacturers to know which one suits your purpose. The two high rolling mills are further divided into two more categories namely high non-reversible machine in which rollers rotate in only one direction, and the workpiece can be fed in only one direction. On the other hand, the second one high reversible machine, which both rollers rotate in both directions. 2.Three High Rolling MillsThe Three High Rolling Mills comprises of a roll stand with three parallel rolls one above another. The adjacent rolls rotate in the opposite direction to pass the material between the top and middle roll in single direction, and the bottom and central roll in the opposite direction. The workpiece is rolled on both forward and return passes. The workpiece passes through the bottom and intermediate rolls, and returns between the middle and top rolls. Various steel roll manufacturers provide top-quality roll mills to meet every type of industrial requirement. 3.Four High Rolling MillsThe Four High Rolling Mills have a roll stand with four parallel rolls placed one above another. The top and bottom rolls work in the opposite direction. The two in the middle are smaller than the top and bottom rolls, which are also known as backup rolls. 4.Tandem Rolling MillsThe Tandem Rolling Mills comprises of a set of two or three strands of roll set in parallel alignment. A continuous pass might be possible through each one with the change in the direction of the material. Many mill rolls manufacturers provide quality tandem rolling mills to various industries. 5.Cluster Rolling MillsCluster Rolling Mills is a first four high rolling mills, where each of the working rolls is backed up by two or more larger rolls for rolling hard material. At times, one might need to employ work rolls of minimum diameter ferent...