Roll Forging.

Roll Forging.

 Roll Forging is a deformation process

used to reduce the cross section of a
cylindrical or rectangular work piece
by passing it through a set of
opposing rolls that have grooves
matching the desired shape of the
final part.
 Roll Forging.
 Roll Forging is classified as Forging
process even though it utilizes rolls.
 Rolls do not turn continuously in roll
forging but rotate through only a
portion of one revolution
corresponding to the desired
deformation to be accomplished on
the part.
Roll Forging.
 Roll Forging.
 Roll Forged parts are generally
stronger and possess favorable grain
structure compared to competing
processes such as machining that
might be used to produce the same
part geometry.
 Roll Forging products.
 In roll forging round or flat bar stock
is reduced in thickness and increased
in length to produce such products
as axles, tapered levers and leaf
springs.
 Swaging.
 Swaging is a process used to reduce
the diameter of a tube or solid rod.

 Swaging is often performed on the

end of a work piece to create a
tapered section.
Examples of Parts made by
Swaging.
 Swaging.
 Swaging process
as shown in
figure is
accomplished by
means of rotating
dies that hammer
a work piece
radially inward to
taper it as the
piece is fed in to
the dies.
 Swaging.
 In swaging die the die
itself acts as hammer.
Repeated blows are
delivered from various
angles , causing the
metal to flow inward
and assume the contour
of the die.
 Most of the swaging is
usually performed cold.
 Swaging.
 Some swaging
processes are
performed hot .
For example hot
swaging is used
to reduce and
form the end of
a pressurized
gas cylinder.
 Net shape and near net shape
Forging.1
 To minimize both the expense and waste
considerable effort has been made to
develop processes that can form parts
close enough to final dimensions that little
or no final machining is required.
 These are referred to as net shape or near
net shape processes and may also be
referred to as precision forging.
 Net shape and near net shape
Forging.2
 Cost savings usually result from the
elimination of reduction or
elimination of secondary machining ,
the companion reduction in scrap
and an over all decrease in the
amount of energy required to
produce the product.
 Net shape and near net shape
Forging.3
 Design and implementation of net
shape processing can be rather
expensive ,application is usually
reserved for parts where a significant
cost reduction can be achieved.
 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.

 Extrusion may be performed either hot or

cold , hot extrusion is commonly employed
for many metals to reduce the forces
required.
 Extrusion.2
 Extrusion process is like
squeezing tooth paste out
of a tube.
 In the case of metals a
common arrangement is
to have a heated billet
placed inside of confining
chamber.
 A ram advances from one
end ,causing the billet to
first upset and conform to
the confining chamber.
 Extrusion.3
 As the ram
continues to
advance the
pressure builds
until the
material flows
plastically
through the die
and extrudes.
 Extrusion.( Materials)
 Aluminum ,Magnesium ,copper , Lead , and alloys of
these metals are commonly extruded , taking
advantage of the relatively low yield strength and
low hot working temperature.
 Steel , stainless steel ,Nickel based alloys and
titanium based alloys are far more difficult to
extrude. Their yield strength and the metals have
the tendency to weld to the walls of the die and
confining chamber under the required
conditions of temperature and pressure.
 Extrusion.( Materials)2
 With the development and use of
phosphate based and molten glass
lubricants ,hot extrusion can be routinely
produced from these high strength , high
temperature metals.

 These lubricants are able to with stand the

required temperatures and adhere to the
billet, flowing and thinning in a way that
prevents metal to metal contact through
out the process.
 Extrusion.
 Almost any cross sectional
shape can be extruded from
the non ferrous metals.

 Size limitations are few

because presses are now
available that can extrude any
shape that can be enclosed
with in 75 cm diameter circle.
 In the case of steels and other
high strength metals the
shapes and sizes are a bit more
limited
Extrusion Products.
 Extrusion.
 Extrusion has a number of attractive
features .many shapes can be produced as
extrusions that are not possible by rolling
such as longitudinal holes.
 No draft is required.
 Billet to product cross sectional area ratios
can be 100 to 1 for the weaker metals.
 The major limitation of the process is the
requirement that the cross section be
uniform for the entire length of the product.
 Extrusion.
 Extrusion products have good surface
finish and dimensional precision.
 For most shapes tolerances of ±0.003
cm/cm easily attainable.
 Grain structure is typical of other hot
worked metals but strong directional
properties ( longitudinal versus transverse
) are usually observed.
 Standard product lengths are about 6 to 7
m but lengths in excess of 12 m have
been produced.
 Extrusion methods.
 Extrusions can be produced by
various techniques and equipment
configurations.
 Hot extrusion is usually done by two
methods:
1. Direct
2. In Direct
 Direct Extrusion.
 In direct extrusion a
solid ram drives the
entire billet to and
through a stationary
die and must provide
additional power to
over come the
frictional resistance
between the surface
of the moving billet
and the confining
chamber.
 Direct Extrusion.
 One of the problems in direct extrusions is
the significant friction that exist between
the work surface and the walls of the
container as the work piece is forced to
slide toward the die opening.

 This friction causes a substantial increase

in the ram force required in direct
extrusion.
 In Direct Extrusion
 In Indirect extrusion
the die is mounted to
the ram rather than at
the opposite end of
the container. As the
ram penetrates in to
the work , the metal is
forced to flow through
the clearance in a
direction opposite to
the direction of
motion of the ram.
 In Direct Extrusion

 Since the work is not forced to

move relative to the container ,
there is no friction at the container
walls and the ram force is
therefore lower than the direct
extrusion.
Direct and In direct
extrusion.
 In Direct
Extrusion( Limitations)
 Added complexity of the in direct process
serves to increase the purchase price and
maintenance cost of the required
equipment.

 In direct extrusions are imposed by the

lower rigidity of the hollow ram .
 Extrusion speeds.
 Speeds of the hot extrusion process are fast so as to
minimize the cooling of the billet with in the chamber.

 Extruded products can emerge at rates up to 300 m/min.

 Extrusion speeds may be restricted by the large

amounts of heat that are generated by the massive
deformation and the associated rise in temperature.
 Extrusion speeds 2
 Sensors are often used to monitor the
temperature of the emerging product and
feed this information back to a control
system.
 For materials whose properties are not
sensitive to strain rate , ram speed may
be maintained at the highest level that
will keep the product temperature below
some predetermined value.
 Extrusion speeds
 Lubrication is another important area
of concern.
 If the reduction ratio is 100 the product
will be 100 times longer than the
starting billet and if the product has a
complex cross section its perimeter
will be considerably larger than the
starting material.
 Extrusion lubricant
 Surface area of the product is the length
times the perimeter as the length and
perimeter both increased the surface area
of the final product will be greater than
the surface area of the starting work
piece.
 A lubricant that is applied to the starting
piece must thin considerably as the
material passes through the die and is
converted to the product.
 Extrusion lubricant 2

 An acceptable lubricant is expected

to reduce friction and act as a barrier
to heat transfer at all stages of the
process.
Thank you