1. FORMING AND SHAPING PROCESSES
Dr. Zühal ERDEN
FORMING AND SHAPING PROCESSES
AND EQUIPMENT

2. CONTENTS Rolling Forging Extrusion and drawing Sheet-metal forming
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
CONTENTS
Rolling
Forging
Extrusion and drawing
Sheet-metal forming
Powder Metallurgy
Forming and shaping plastics and composites; Rapid Prototyping
Forming and shaping ceramics and glass
Atılım University / Dept. of Industrial Engineering

3. ROLLING Flat rolling Shape rolling
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
ROLLING
Rolling is the process of reducing the thickess or changing the cross-section of a long workpiece by compressive forces applied through a set of rolls
Flat rolling
Shape rolling
Atılım University / Dept. of Industrial Engineering

4. Flat Rolling IE 204 Manufacturing Processes Dr. Zühal ERDEN
Atılım University / Dept. of Industrial Engineering

5. Shape Rolling IE 204 Manufacturing Processes Dr. Zühal ERDEN
Atılım University / Dept. of Industrial Engineering

6. Straight and long structural shapes
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Applications
Straight and long structural shapes
Solid bars with various cross sections
Channels
I-beams
Railroad rails
Atılım University / Dept. of Industrial Engineering

7. Production of Seamless Tubes and Pipes
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Production of Seamless Tubes and Pipes
Rotary Tube Piercing (The Mannesmann Process)
Hot-working process
Radial compressive forces  tensile stress at the center of the bar
Cyclic compressive stresses  cavity formation
Diameter of tubes and pipes are reduced by tube rolling
Atılım University / Dept. of Industrial Engineering

8. IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atılım University / Dept. of Industrial Engineering

9. IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Forging
Press or forging hammer
Discrete parts (bolts and
rivets, connecting rods, shafts for turbines, gears,hand tools, structural components for machinery)
Cold forging (at room temperature)
Warm or hot forging (at elevated temperatures
Forging is the name for processes whereby the workpiece is shaped by compressive forces applied through various dies and tools
Atılım University / Dept. of Industrial Engineering

10. Open-die forging IE 204 Manufacturing Processes Dr. Zühal ERDEN
Atılım University / Dept. of Industrial Engineering

11. Impression-die and Closed-die Forging
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Impression-die and Closed-die Forging
Atılım University / Dept. of Industrial Engineering

12. IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atılım University / Dept. of Industrial Engineering

13. Related forging operations - Heading
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Related forging operations - Heading
Atılım University / Dept. of Industrial Engineering

14. Piercing IE 204 Manufacturing Processes Dr. Zühal ERDEN
Atılım University / Dept. of Industrial Engineering

15. Die Materials General requirements for die materials:
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Die Materials
General requirements for die materials:
Strength and toughness at elevated temperatures
Herdenability and ability to harden uniformly
Mechanical and thermal shock resistance
Wear resistance (abrasive wear resistance)
Common die materials: tool and die steels containing chromium, nickel, molybdenum and vanadium
Atılım University / Dept. of Industrial Engineering

16. Economics of Forging IE 204 Manufacturing Processes Dr. Zühal ERDEN
Atılım University / Dept. of Industrial Engineering

17. IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atılım University / Dept. of Industrial Engineering