Course Title: Metal Forming (Pr-603) Lecture Note: Instructor In-Charge: Dr. Raj Ballav
Course Title: Metal Forming (Pr-603) Lecture Note: Instructor In-Charge: Dr. Raj Ballav
Course Title: Metal Forming (Pr-603) Lecture Note: Instructor In-Charge: Dr. Raj Ballav
EXTRUSION
TYPE OF ROLLING MILL
ROLLING :
o Rolling constitute a group of processes in which
deformation or change in shape of product is brought
about by compression between rotating cylindrical rolls.
o Rolling of metals is the most important metal forming
process where 95% of production of ferrous and non-
ferrous alloys goes through this process.
TWO ROLLING MILL :
o This mill consist two rollers.
o Both the rollers rotate in opposite direction for desire
movement of work piece.
o Work piece is feed between the rollers which apply a
compressive force and tends to plastically deform work
piece and convert it into desire shape.
THREE ROLLING MILL :
o This type of rolling mill consist three rollers arrange parallel
to each other.
o In this machine the middle roller rotate in opposite
direction of other two rollers.
o This machine is used to reduce two times thickness in one
pass.
o In this machine, the work piece is feed between bottom
and middle roller in one direction and top and middle
rollers in opposite direction. This machine can handle two
work pieces in single run.
FOUR ROLLING MILL :
• These machine consist four rollers (two small and two big).
• Big rollers works as backup rolls and they also rotates in
opposite direction with each other and also with contact
roller.
• This machine is used for cold rolling where high rigidity
required.
ELECTOHYDRAULIC FORMING
HEAT TREATMENT :
Purpose of heat treatment-
To improve machinability.
To change or refine grain size.
To relieve the stresses of the metal induced during cold and
hot working.
To improve mechanical properties(Tensile strength,
Hardness, Ductility, Shock resistance).
To increase resistance to wear heat and corrosion.
To produce a hard surface on a ductile interior.
The most commonly used operation of heat treatment :
Annealing
Normalizing
Hardening
Tempering
Carburizing (case hardening)
Cyaniding
Nitriding
Induction Hardening
Flame Hardening
ANNEALING:
The objective of annealing are:
• To soften the metal so that it can be cold worked.
• To reduce hardness and improve machinability.
• To refine grain size due to phase recrystallization and produce
uniformity.
• To increase ductility of metal.
• To prepare steel for subsequent heat treatment.
• To obtain desired mechanical , physical , electrical and magnetic
property.
• To relieve internal stresses .
• To produce a desired microstructure.
NORMALIZING:
• Normalizing heat treatment is a heat treating process used
to provide uniformity in grain size and microstructure in
some steel grades.
• Normalizing is the process of heating a material to a
temperature above a critical limit and then cooling in open
air.
HARDNING:
CARBURIZING:
• carburization is a heat treatment process in
which iron or steel absorbs carbon while the metal is heated in
the presence of a carbon-bearing material, such as charcoal
or carbon monoxide. The intent is to make the metal harder.
Depending on the amount of time and temperature, the
affected area can vary in carbon content.
CYANIDING:
• Cyaniding is a case-hardening process that is fast and
efficient.
• it is mainly used on low-carbon steels.
NITRIDING:
• Nitriding is a case-hardening process in which nitrogen is
introduced into the surface of a ferrous alloy such
as steel by holding the metal at a temperature below that
at which the crystal structure begins to transform to
austenite on heating.
INDUCTION HARDENING:
• Induction hardening is a type of surface hardening in which
a metal part is induction-heated and then quenched.
• The quenched metal undergoes a martensitic
transformation, increasing the hardness and brittleness of
the part.
FLAME HARDENING:
• Flame hardening is a common surface hardening method.
Metal surfaces, such as steel, are heated with a high-
temperature flame and then quenched.
• The result of flame hardening is a hard surface that is more
resistant against wear and corrosion.