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MCHE 365 Manufacturing Processes

Metalworking processes in which the workpiece is subjected to plastic deformation under forces applied through various dies and tooling correct answers Bulk Deformation Processes Bulk Deformation Processes: Generally classified by type of ___: • Primary working (___) • Secondary worki...

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metalworking processes in which the workpiece is s

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Metalworking processes in which the workpiece is subjected to plastic deformation under forces
applied through various dies and tooling correct answers Bulk Deformation Processes

Bulk Deformation Processes:

Generally classified by type of ___:
• Primary working (___)
• Secondary working (___)
• Hot, warm, cold (___) •

___, ___, ___ important design considerations

Used to make discrete parts under ___ stresses, dates back to ___ B.C. (ex: sword making)
correct answers operation

cast ingot to wrought

finished products

T/Tm

stresses, strains, strain rates

compressive, 5000

____________: (Type of Bulk Deformation)

• Operations that involve taking a solid piece of metal (generally from a cast state) and breaking
it down successively into wrought materials of various shapes

Done by the processes of ___, ___, ___, and ___

___ properties (mechanical) generally better than cast correct answers primary working

forging, rolling, extrusion, drawing

forged

__________: (Type of Bulk Deformation)

,Operations that involve further processing of the products from primary working into final or
semifinal products, such as bolts, gears, and sheet-metal parts correct answers secondary
working

In ___, parts have relatively small surface-area-to volume (or to thickness) ratio - distinction to
sheet metal.

Examples:
• ___
• ___
• ___ correct answers bulk deformation

hand tools
shafts
turbine disks

____________:

• A family of processes to make discrete parts in which plastic deformation takes place by
compressive forces applied through various dies and tooling

• One of the oldest metalworking operations known

• Dates back to ___ B.C.

• Can be carried out at room temperature ( ___ ) or elevated temperatures ( ___ or ___)

• Open ___/Closed ___ correct answers Forging

5000

cold working

warm, hot forging

die

_________________:

Caused by friction

• Can be minimized by applying an effective lubricant or ultrasonic vibrations of the platens

Double ___ can occur:
• In slender specimens with high ratios of ___ to cross-sectional area

,• When friction at the die-work piece interface is very ___ correct answers Barreling

barreling

height

high

Types of forging (5 items) correct answers Impression Die
Precision
Closed die
Isothermal
Incremental

_________:

Workpiece acquires the shape of the die cavity while it is being deformed by the closing dies

• The formation of a flash ( ___ ) must be cut off

• ___ range between 0.5% and 1% ±

• ___ depends on blank preparation, die surface finish, wear, lubricant

• ___ is an important property in accounting for die geometry correct answers impression die
forging

excess material

tolerances

surface finish

flash

The part formed is close to the final desired dimensions by using special dies made to a higher
accuracy correct answers precision forging

No flash (excess material) is formed and the workpiece is completely surrounded by the dies
correct answers closed die forging

Dies are heated to the same temperature as the hot blank. Cooling is eliminated. correct answers
Isothermal Forging

Blank is formed in several small steps using lower forces (Archard Wear Law) correct answers
Incremental Forging

, other forging operation:

• Slug is shaped in a completely closed cavity to produce fine details

• May or may not have flash correct answers Coining

other forging operation:

Typically performed at the end of a rod to produce a shape with a larger cross section correct
answers Heading

other forging operation:

Punch indents the work piece surface to produce a cavity or impression with a specific shape
correct answers Piercing

other forging operation:

Cross sectional area of a bar is reduced and altered into a shape by passing it through a pair or
sets of grooved rolls of various shapes correct answers Roll Forging

other forging operation:

hardened punch more shallow than piercing correct answers Hubbing (cold-working)

other forging operation:

reduction in thickness by die compression correct answers Cogging (drawing out)

other forging operation:

material distribution in bar stock correct answers Fullering & Edging

other forging operation:

ball bearings correct answers Skew Rolling

Forging Characteristics:

Effect of ___ pressure
• Causes cracking to require higher ___ levels

Defects:
• ___ material
• ___ flow pattern

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