Bulk
Processing Module
Outcomes
1. Be able to compare (similarities
and differences, advantages and disadvantages) between the various bulk
processes: forging, rolling, bending, shearing, extrusion,
drawing and deep drawing.
2. Be able to connect the scientific
principles, engineering challenges, and non-technical (business, safety etc) for each process
Preparation
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Text
Sections. The first two paragraphs of Chapter 17 are a great overview. Other
modules in this course will focus on material properties. Please pay careful
attention to Figure 17.1 and the accompanying text. It is important to
differentiate between bulk and sheet processing. Please pay careful attention
to the sloppy use of the term drawing. The sheet metal process called drawing
will be referred to as deep drawing, and although wire drawing is the most
common process – pulling material through a die, we will refer to all pulling
through a die processes as drawing.
Sections 17.2-17.6 are beyond the scope of this course, and may not be
completely correct. The introduction to Chapter 18 is excellent. However as you
read Sections 18.1, 18.3, 18.5, and 18.6 ignore references to true-stress and
true-strain, in the presentation and basic class notes I converted the relevant
formulae to properties obtainable from an engineering stress-strain curve. As
you read Chapter 19, please note that all references to drawing should be
labeled “deep-drawing”.
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The
following videos from the text. The hot
forging video is a good introduction to the forging process. As you view
this, note the sequence of steps – especially those associated with finish
forging. Try to relate finish forging to the role of the riser in casting. The open
die forging video, shows how some parts formed by casting could be prepared
for further machining. Again focus on the steps and the nearer-net-shape
produced. I need to look at the overall
forging video in more detail, I am not certain the connection to
microstructure is correct. The bending
video shows not only the current practices but a concise and accurate
analysis of the engineering considerations associated with bending. The Shearing
video, provides an excellent overview of cutting but all references to the
slip plane are wrong. The basic
forming video focusing on cutting and forming techniques. Metal
formability as it relates to sheet metal forming is a good overview but
note what they call drawing, we call deep drawing. The YouTube Video on Aluminum Extrusion shows
how extrusion occurs, please focus on pushing through a die, not aging etc. The
YouTube video on Steel
Rolling focuses on m-rolling and is good.
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Sheet
Metal Forming Experience Provided for Freshmen at
Kettering. Focus not only on how the processes relate to bulk processing in
general, but on the details of the procedures. You may want to compare these to
your notes from the reading and the videos. You may want to refer to these
later in the course when ISO and Safety are discussed.