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Cold Forging Process Overview

Cold working processes have several advantages: (1) strain hardening increases strength allowing weaker starting materials, (2) proper annealing positions allow a final product with specified cold work, and (3) good surface finish and precision. Common cold working processes include rolling, forging, extrusion, bending, shearing, drawing, and sheet metal forming. Cold forging produces parts with minimal scrap and favorable grain flow for increased strength with little need for machining. Wire and tube drawing use dies to reduce the cross-section of wire or tubes.

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28 views27 pages

Cold Forging Process Overview

Cold working processes have several advantages: (1) strain hardening increases strength allowing weaker starting materials, (2) proper annealing positions allow a final product with specified cold work, and (3) good surface finish and precision. Common cold working processes include rolling, forging, extrusion, bending, shearing, drawing, and sheet metal forming. Cold forging produces parts with minimal scrap and favorable grain flow for increased strength with little need for machining. Wire and tube drawing use dies to reduce the cross-section of wire or tubes.

Uploaded by

Anil
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd

MET 203

Manufacturing Processes I
Mechanical Engineering

Cold-Working Processes
Technology

Fall 2005 Wolfgang J. Sauer


What you will learn in this lecture
• What are the advantages of cold-
working processes
• How cold heading/upsetting work
• The advantages of hydrostatic
Mechanical Engineering

extrusion
• How to control fracture in
shearing operations
• How to achieve tooling cost
Technology

reductions
• What are the limitations in wire
drawing
Advantages
• Cold forming processes are generally used
to produce semi-finished goods.
• Strain hardening acts to increase the
Mechanical Engineering

strength of the material, so cheaper,weaker


starting materials may be selected.
• By properly positioning the last anneal, a
final product can be produced with a
Technology

specified amount of cold work.


• Surface finish and dimensional precision are
quite good.
Cold-Working Processes
• Squeezing Processes
– Rolling
– Thread Rolling
– Forging
– Extrusion
Mechanical Engineering

• Bending
• Shearing
– Simple Shearing
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– Piercing and Blanking


• Drawing and Sheet Metal Forming
– Wire Drawing
– Sheet Metal Drawing
Mechanical Engineering
Technology Cold Heading
Cold Forging
Mechanical Engineering
Technology

Cold forging can produce parts with minimal amount of scrap.


Grain Flow in Cold Forging

This spark plug body was


cold forged. The section
shows the favorable grain
flow which increases part
Mechanical Engineering

strength.
Dimensional accuracy is
good, so little or no
secondary machining is
Technology

needed.
Mechanical Engineering
Technology Preform Steps in Cold Forging
Mechanical Engineering
Technology

Production of Cold-Formed Bolts


Mechanical Engineering
Technology Hydrostatic Cold Extrusion
Mechanical Engineering
Technology Extrusion Profiles
Mechanical Engineering
Technology
Video Credits: The video clip on this page was taken from the
SME Sampler DVD that accompanies our textbook.
Sheet Metal Forming
Blanking & Piercing
Mechanical Engineering
Technology

Simple blanking with a punch and die


Mechanical Engineering
Technology
Video Credits: The video clip on this page was taken from the
SME Sampler DVD that accompanies our textbook.
Shearing Operations
Mechanical Engineering
Technology Shearing Operation
Changing the State of Stress
Obtaining a smooth edge in
shearing by putting the metal
in localized compression and
a squeezing ejector.
Mechanical Engineering

Stock skeleton after


Technology

shearing, showing the


compressed indentation.
Mechanical Engineering
Technology Fine Blanking
Mechanical Engineering
Technology Components of Blanking Dies
Mechanical Engineering
Technology
Die Set with Alignment Posts
Mechanical Engineering
Technology Self-contained Subpress Tooling
Mechanical Engineering
Technology Compound Die
Mechanical Engineering
Technology Progressive Blanking Die
Mechanical Engineering
Technology Inclined Blanking Press
Mechanical Engineering
Technology Mechanical Press Drives
Wire Drawing
a) Principle of
operation
Mechanical Engineering
Technology

b) Die design
Wire Drawing – Die Design
a) Schematic process
Mechanical Engineering
Technology

b) Draw bench
Tube Drawing
Mechanical Engineering
Technology

a) without mandrel b) stationary mandrel


c) Floating mandrel d) moving mandrel

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