Forming Proses

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Bulk Deformation Forming - Rough Shapes Overview of Lecture 3 Definitions General characteristics of forming processes Individual Bulk Deformation Processes Rolling Extrusion Forging Open Die Closed Die Other Die Design Forging machines Forging economics Comparison of Forging and Casting Overview - Shaping and Forming Finishing Ingot casting Molten Material Powders Casting Shapes Rolling Forging/ Press forming Stamping Pressing Sheet metal forming Continuous Casting/Rolling Injection Molding Machining Raw Material Special Extruding Single crystal pulling Firing/ Sintering SLS Increasing level of detail Blow molding Definitions of Shaping and Forming Forming - changing the shape of an existing solid body or workpiece, stock or blank by applied forces to cause plastic flow Usually involves minimal scrap (flashing) Low buy to fly ratio Shaping - usually means removal of material Milling, drilling, turning, carving, etc. Lots of scrap High buy to fly ratio Kalpakjian Definition of Shaping molding or casting Bulk Deformation Processes Start with a cast ingot in a particular shape Process in a machine which causes gross or bulk deformation to provide a new shape Can only use these processes when the material has a plastic regime in its stress strain behavior. Most metals Most plastics Some materials must be formed hot to obtain plastic behavior Some metals Some plastics Inorganic glasses above their transition range Bulk Deformation Processes The resultant shape is usually further worked or shaped. Total deformations can be very large Foil 5000 Canstock 1400 Typical sheet 400 Typical Plate 3 Extrusions 8 Deformation = initial dimension/final dimension Bulk Deformation Processes Rolling typically starts with a rectangular ingot and results in rectangular Plates(t>6mm) Rolls of thin sheet (t