‫بسم هللا الرحمن الرحيم‬

Manufacturing Processes
0703314
Chapter 4
Bulk Deformation Processes
 Objectives
• To understand the basic concepts of bulk
deformation processes.
• To study the types of bulk deformation
processes.
• To study hot and cold deformation processes

• To understand the mechanisms of lubrication.

2
 Introduction
Industrial deformation processes are divided
into two parts:
1- Bulk deformation processes in which the
whole volume of the workpiece is
deformed.
2- Sheet metal forming processes in which
there is only localized plastic deformation,
typically involving a change in sheet
thickness. 3
 Bulk Deformation Processes

Rolling Forging

Extrusion Drawing 4
 Bulk Deformation Processes
- The deformation may occur in all region
of the workpiece, so they require
contact between the working surfaces
(dies or rolls) and the workpiece.
- The sample may be very small or large
samples.
- Metals can be deformed either by hot or
cold deformation processes.
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 Bulk Deformation Processes
(a) Hot Deformation
- (T>T recrystallization) above 0.5 absolute Tm.
- It produces greater deformation and requires
lower forming energies.
(b) Cold Deformation
- It occurs below 0.3 absolute Tm.
- It produces improved surface finish and
increases the strength of the product due
to strain hardening. 6
 Lubrication
The application of the lubricant has many
desirable attributes such as:
(a) reducing the friction.
(b) protection of the surfaces from wear.
(c) ability to remove heat from the die-
workpiece interface.

7
 Lubrication Mechanisms
Hydrodynamic Lubrication
i- A large velocity between the two surfaces.
ii- A continuous film of lubricant is used .
iii- Mineral oils are used.
Boundary Lubrication
i- A thin film of lubricant is used.
ii- Organic substances such as fatty acids
and soaps are used.
iii- Mechanism is suitable at low
temperatures.
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 Lubrication Mechanisms
Mixed Film Lubrication
i- A combination of hydrodynamic and
boundary lubrication.
ii- The lubricants are mineral oils with some
additives.
Solid Film Lubrication:
i- Solids are used to separate the die and the
workpiece.
ii- Effective at low velocity and at high
temperatures.
iii- Graphite, molybdenum disulfide and glasses
are used. 9
 Conclusions
• Industrial deformation processes are
divided into two classes: bulk and
sheet deformation processes.
• Bulk deformation processes include
rolling, forging, extrusion, and drawing
processes.
• Hot deformation processes are
performed at a temperature higher
than 0.5 Tm (K).
10
 Conclusions
• Cold deformation processes are
performed at a temperature lower than
0.3 Tm (K).
• Lubricants are used to reduce friction
during manufacturing processes.
• There are four mechanisms of
lubrications: Hydrodynamic, Boundary,
Mixed Film, and Solid Film Lubrication.

11
 Objectives
• To study the types of forging.
• To study cold and hot upsetting of a
cylinder.
• To study upsetting of a cylinder with
friction.
• To study forging of rectangular
workpeice.

12
 Forging

(a) Open Die, (b) Closed die,

and (c) Impression Die Forging. 13
 Forging
Open Die Forging
- Not suitable for complex shapes.
- The tools are less complicated and
expensive.
Closed Die Forging
- Suitable for complex shapes.
- The tools are more complicated and
expensive.
- Complete filling must be achieved
without breaking the die. 14
 Forging
Impression Die Forging
- Suitable for complex shapes.
- Flash cutters are found in the remove the
flash
The mechanical properties of the forged
parts are higher than those of cast due to:
1- The formation of a grain structure which
is elongated in the direction of
deformation.
15
 Forging
2- The recrystallization process which
produces a fine grain microstructure.
3- Elimination the cast dendritic
structure that has poor properties.
Cold and Hot Upsetting a Cylinder
- Cold deformation occurs at T < 0.3 Tm.
- Hot deformation occurs at T > 0.5 Tm.

16
Cold and Hot Upsetting a Cylinder
- During the hot deformation strain
hardening and dynamic recrystallization or
dynamic recovery may occur.
- Dynamic recrystallization and dynamic
recovery cause softening due to
annihilation of dislocations.
- The stress required for hot deformation
represents the dynamic equilibrium
between the hardening processes and the
softening processes. 17
Cold and Hot Upsetting a Cylinder
- Dynamic recrystallization and recovery
occur via diffusion process.
- The deformation properties of the metals
depend on the rate time during the process.
Upsetting a Cylinder with Friction
Friction free upsetting is unrealistic in
practice due to the development of friction
between the die and the workpiece.
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 Upsetting a Cylinder with Friction
The stress required for deformation including
friction is given as:
 a  Qa  t
- Where Qa is the multiplying factor which depends
on the friction coefficient and the geometry.
- The deformation force is given as:

F Q
- Where Am is the mean a  t Am
cross-sectional area of the
work piece.
19
Multiplying Factor for Forging

20
Forging of Rectangular Workpiece
If w >10 L, the deformation takes place in two
directions.

21
Forging of Rectangular Workpiece
The interface pressure is given as
 p  Q p t

22
 Conclusions
• There are three types of forging
operation: they are open die, closed die,
and impression forging.
• The choice of forging type depends on
the shape of the product.
• The mechanical properties of the forged
parts are higher than those of cast parts.
• The force required for forging depends
on the process type, the product shape,
and the friction coefficient. 23
 Objectives
• To understand the basic principles of
extrusion process.
• To study the types of extrusion process.
• To study both cold and hot extrusion
processes.
• To study the processing variables of the
process.
• To understand some mathematical
equation that used to calculate the force
required to carry out the process. 24
 Extrusion Process
• Extrusion process is used to shape
metals by forcing it to pass through
out a suitable die.
• Extrusion presses are hydraulic with a
force range between 15000 and
45000 kN.
• There are two types of extrusion, cold
and hot extrusion processes.
25
 Extrusion Process
• Cold extrusion processes give better
surface finish and higher strength,
while hot extrusion processes require
lower force and give fine grain
microstructure.

26
 Forward Extrusion

• It is the most common process.

• It is used for hot extrusion of metals.
• Dead zones are found. 27
 Backward Extrusion

• The ram moves in an opposite direction.

• Dead zones are found.
28
 Impact Extrusion

• It is used to produce collapsible tubes or

containers.
• A punch impacts a metal at high velocity
and forces. 29
 Extrusion Process

Processing Variables
• Temperature.
• Pressure (Velocity).
• Rate of cooling.
• Friction force.

30
 Conclusions
• There are three types of extrusion:
Forward, Backward, and Impact.
• Extrusion may be hot or cold
process.
• Several processing variables must
be controlled during the process,
such as the temperature, the
pressure, the rate of cooling, and
friction forces.
31
 Objectives
• To understand the basic principles of
Rolling and Drawing processes.
• To study the processing variables of
each process.
• To understand some mathematical
equation that used to calculate the
force required to carry out each
process.
32
 Drawing
• It is a process for the fabrication of long
lengths of small diameter wire with good
dimensional accuracy.
• The rate at which the product can be drawn
is very high (up to 50 m/s).
• The applied force is limited by the yield
strength of the product in order to avoid
deformation of the product after leaving the
die.
33
 Drawing

3 .2
d  t(
  0.9
)(   ) 

  1  (1  r ) 0.5
r
 2

Ae
r  1
A0 34
 Rolling
It is used to reduce the cross-section of large
ingots or plate for production finished and
semi-finished components.

35
 Rolling

Large back-up rolls that provide increased

Stiffness and prevent the work rolls from
bowing due to the rolling pressure 36
Rolling

37
Geometry of Flat Rolling

L R ( h0  h1 ) 38
 Rolling Force and Power

If h/L < 1, the roll pressure Pr   t Q p

*
v h0
Fr  LwQ p t  m
 ln
L h1

T  Fr L P  T
39
 Conclusions
• Drawing is a process used to produce long
products with small cross sectional area.
• The applied stress depends on many
parameters such as the materials type, the
die angle, the initial and final cross
sectional area, and the friction coefficient.
• Rolling is a process used to reduce the
thickness of large ingots or plates.

40
 Conclusions
• Several rolls can be used in this process.
• The force required for this process
depends on several parameters such as
the contact length, the width of the roll,
the materials type, the geometry of the
product, the friction coefficient, and the
processing temperature.

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