Term
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Definition
| Force necessary to plow the peaks of a harder material through a softer one |
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Term
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Definition
| Force necessary to rip apart microscopic weldments that form between the two materials |
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Term
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Definition
is related to the distorted crystal structure, and is not simply a function of the nonmetallic inclusions.
-properties vary with direction |
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Term
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Definition
| Heat treatment often applied to a metal prior to cold working as a means of maximizing the amount of starting ductility. |
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Term
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Definition
| type of deformation; sometimes done to produce wire etc |
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Term
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Definition
| Deformation may be __________in three dimensions |
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Term
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Definition
| The proportionality constant, u...Relationship between the friction constant and the contact pressure. |
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Term
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Definition
| The plastic deformation of metals below the recrystallization temperature |
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Term
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Definition
| The mathematical descriptions of material behavior as a function of the process conditions are known as ___________. |
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Term
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Definition
These processes have been designed to exploit a remarkable property of some engineering materials known as plasticity.
-To further our knowledge of shape production alternatives, we will continue out survey by considering the family of __________. |
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Term
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Definition
| these are consequences of the independent variable selection. |
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Term
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Definition
| Characteristic of the resultant product that is dependent on the specific details of the process. (??How exact the dimensions are) |
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Term
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Definition
| A linear defect or irregularity within crystal structure |
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Term
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Definition
| The decrease in stain, X3-X2 |
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Term
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Definition
| resulting ridges and valleys that are very difficult to remove. Also know as Luders Bands |
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Term
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Definition
| Is the resistance to sliding along an interface. |
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Term
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Definition
| The plastic deformation of metals at a temperature above the recrystallization temperature |
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Term
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Definition
| those aspects of the process over which the engineer has direct control, and they are generally selected or specified when setting up the process. |
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Term
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Definition
| If the required amount of deformation exceeds the fracture limit, _________ may be performed to restore ductility, thereby enabling further working without the danger of fracture. |
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Term
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Definition
| Deformation preformed under constant temperature conditions. |
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Term
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Definition
Is a key to success in many metalforming operations.
Act as coolants, thermal barriers, corrosion inhibitors, and parting compounds. |
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Term
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Definition
| resulting ridges and valleys that are very difficult to remove. Also know as Stretcher Strains |
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Term
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Definition
| Imparted by the flow of the material, which controls the shape of the various cavities |
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Term
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Definition
| the ability to flow as solids without deterioration of their properties. |
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Term
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Definition
| If the metal has experienced a sufficient amount of deformation, the distorted structure will be rapidly replaced by a new strain-free grains |
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Term
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Definition
| ?? Type of Deformation. (Cutting of metal with a blade.) |
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Term
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Definition
| Materials that appear to be stronger when deformed at higher speeds |
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Term
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Definition
| When a metal is deformed by the application of a load, part of the resulting deformation is elastic. |
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Term
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Definition
| Strength levels induced by _______ are often comparable to those produced by strengthening heat treatments. |
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Term
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Definition
| Luders bands; ridges and valleys resulting from cold working deformation |
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Term
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Definition
| when metal is plastically deformed the fracture into rows of fragments |
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Term
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Definition
| Characteristic of the resultant product that is dependent on the specific details of the process. (??What the final surface looks like) |
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Term
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Definition
| Will induce and control the metal flow as the material goes from starting shape to finished product |
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Term
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Definition
| the study of friction and lubrication |
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Term
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Definition
| Deformations produced at temperatures intermediate to hot and cold forming is know as ________. |
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Term
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Definition
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Term
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Definition
| The material can strain up to several percent with no additional force being required. |
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Term
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Definition
Highly automated upset equipment in which mill-length steel bars are fed into one end at room temperature and hot-forged products emerge form the other end at rates of up to 180 parts per minute.
has a number of attractive features. Low-cost input material and high production speeds have already been cited. |
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Term
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Definition
| A Semi-finished shape that are furthered rolled from billets or blooms |
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Term
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Definition
| Usually smaller than a bloom and has a square or circular cross section. |
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Term
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Definition
| Intermediate impressions are for _____ the metal to approximately its final shape, with generous corner, and fillet radii. |
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Term
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Definition
| Has a square or rectangular cross section, with a thickness greater that 15cm and a width no greater than twice the thickness |
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Term
| Bulk Deformation Processes |
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Definition
| Those where the surface area of the workpiece changes significantly. |
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Term
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Definition
| Steel skelp is heated to a specified hot-working temperature by passing it through a furnace. Upon exiting the furnace, it is pulled through forming rolls that shape it into a cylinder and bring the free ends into contact. |
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Term
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Definition
| uses shaped dies in order to control the flow of metal. |
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Term
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Definition
| the roll in contact with the work can be as small as 6mm in diameter. |
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Term
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Definition
| Consists of integrating deformation and thermal processing into a single process that will not only produce the desired shape, but also the desired properties |
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Term
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Definition
| Alternative to the hammer and anvil arrangement that have to horizontal hammers that simultaneously impact a workpiece that is positioned between them. Excess energy becomes recoil. |
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Term
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Definition
| A solid ram drives the entire billet through a stationary die and must provide additional power to overcome the frictional resistances between the surface of the moving billet and the confining chamber. |
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Term
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Definition
| Plastic deformation process in which a flat sheet or plate is formed into a recessed, three-dimensional part with a depth more than several times the thickness of the metal. |
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Term
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Definition
389
Metal is heated to proper temperature by gas, oil or electric furnaces or by electrical induction heating; the impact is then delivered by some type of mechanical hammer. |
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Term
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Definition
| metal is compressed and forced to flow through a suitably shaped die to form a product with reduced but constant cross section. 399 |
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Term
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Definition
| ensures the production of a uniform fine grain size and prevents the possibility of unwanted strain hardening 385 |
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Term
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Definition
| is formed when excess metal is squeezed out around the periphery of the cavity. Ensures the filling of all the cavity details 391 |
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Term
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Definition
| aka true closed-die forging, the metal is deformed in a cavity that provides total confinement. 392 |
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Term
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Definition
| term applied to a family of processes where the deformation is induced by localized compressive forces; usually implies hot forging done above the recrystallization temperature. 389 |
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Term
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Definition
| the act where the die itself acts as the hammer which hammers a rod or a tube to reduce its diameter. 398 |
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Term
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Definition
| move in response to fluid pressure in a piston and are generally slower, more massive, and more costly to operate; more flexible and have a greater capacity. 394 |
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Term
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Definition
| aka counterblow machine—alternative to the hammer and anvil; machines that have 2 horizontal hammers that simultaneously impact a workpiece that is positioned between them. 393 |
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Term
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Definition
| uses shaped dies to control the flow of metal. 391 |
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Term
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Definition
| a hollow ram pushes the die back through a stationary confined billed. 400 |
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Term
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Definition
| if the gap between the punch and the die is less than the thickness of the incoming material, the cup wall is thinned and elongated by a process called ironing. 403 |
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Term
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Definition
| utilizes steel in the form of a skelp; the skelp has beveled edges and the rolls form the weld by forcing the lapped edges down against a supported mandrel. Used for larger sizes of pie. 403 |
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Term
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Definition
| is either an object used to shape machined work; a tool component that grips or clamps materials to be machined; or a tool component that can be used to grip other moving tool components. |
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Term
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Definition
| commonly used in hot piercing; can be used to produce tubing up do 300mm in diameter. 404 |
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Term
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Definition
| use means such as cams, cranks, or toggles to produce a preset and reproductive stroke. Fast and capable of up to 50 strokes per minute. 394 |
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Term
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Definition
| the surfaces of hot-rolled products are usually a bit rough and are originally covered with a tenacious high-temp oxide called mill scale. 387 |
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Term
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Definition
| to minimize both the expense and waste, considerable effort t has been made to develop processes that can form parts close enough to final dimensions that little or no final machining is required. 398 |
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Term
|
Definition
| to minimize both the expense and waste, considerable effort t has been made to develop processes that can form parts close enough to final dimensions that little or no final machining is required. 398 |
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Term
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Definition
| same type of forging done by blacksmith of old, but massive mechanical equipment is now used to impart the repeated blow— 389. |
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Term
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Definition
| a process where two or more layers of metal are rolled simultaneously as a means of providing a thicker input material. 386 |
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Term
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Definition
| a hot-working process; results in a short length of thick-walled seamless tubing, which can be passed through sizing rolls to reduce the diameter and/or wall thickness. 404 |
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Term
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Definition
| blooms and billets can be processed into semi finished shapes such as pipes. 384 |
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Term
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Definition
| large quantities of steel pipe are made by 2 processes that use hot forming of steel strip coupled with the deformation-induced welding of its free edges ( butt welding and lap welding)—uniform in quality 403 |
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Term
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Definition
| slabs can be rolled to produce these. Once hot worked, they often form the starting material for subsequent processing using techniques such as cold forming or machining. 384 |
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Term
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Definition
| used if large pieces or thick products are to be formed. The deformation is now analyzed in terms of forces or pressure and the slow squeezing action penetrates completely through the metal, producing a more deformation and new flow. 394 |
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Term
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Definition
| the initial drawing can be followed by a further reduction in diameter and concurrent increase in wall height if the thinning is objectionable—uses a smaller punch and die. 403 |
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Term
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Definition
| a special rolling process where one roll is placed through the hole of a thick-walled ring, and a second roll pressed in from the outside—as the rolls squeeze and rotate, the wall thickness is reduced and the diameter of the ring increases. 387 |
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Term
|
Definition
| blooms and billets can be processed into semi finished shapes such as rods. 384 |
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Term
|
Definition
| round or flat bar stock is reduced in thickness and increased in length to produce such products as axles, tapered levers, and leaf springs. 397 |
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Term
|
Definition
| the first process that is used to convert materials into a finished wrought product. Thick starting stock can be rolled into blooms, billets, or slabs, or these shapes can be obtained directly from continuous casting. 383 |
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Term
|
Definition
| process that makes thick-walled seamless tubing; 404 |
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Term
|
Definition
| thick walled seamless tubing can be passed through sizing rolls to reduce the diameter and/or wall thickness—can be expanded in diamter by passing them over an enlarging mandrel. 404 |
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|
Term
|
Definition
| slabs can be rolled to produce these. Once hot worked, they often form the starting material for subsequent processing using techniques such as cold forming or machining. – can be fabricated into products or further cold rolled into thinner, stronger material, or even into foil. 384 |
|
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Term
|
Definition
| involves the deformation of a material where the thickness and surface area remain relatively constant. 382 |
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Term
|
Definition
| butt welding and lap welding of pipe utilize steel in the form _____-- of long strips with specified width, thickness, and edge configuration 403 |
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Term
|
Definition
| rectangular solid where the width is greater than twice the thickness- can be further rolled to produce plate, sheet, and strip 384 |
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Term
|
Definition
| used for products with multiple or more complex cavities: hot metal flows around the arms of a “spider” and a further reduction often forces the material back together. 402 |
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Term
|
Definition
| used to produce larger-diameter tubes – uses the same principle but replace the convex rolls of the Mannesmann mill with larger-diameter conical disks. 404 |
|
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Term
|
Definition
| slabs can be rolled to produce these. Once hot worked, they often form the starting material for subsequent processing using techniques such as cold forming or machining- can be fabricated into products or further cold rolled into thinner, stronger material, or even into foil. 384 |
|
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Term
|
Definition
| blooms and billets can be further rolled into finished products such as structural shapes or railroad rail 384 |
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Term
|
Definition
| involves the hammering of a rod or tube to reduce its diameter where the die itself acts as the hammer—also applied to a process where material is forced into a confining die to reduce its diameter, and this process is often performed hot. 398 |
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Term
| Thermomechanical Processing |
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Definition
| integrating deformation and thermal processing into a single process that will produce not only the desired shape, but also the desired properties, such as strength and toughness. Ex. Controlled rolling 389 |
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Term
|
Definition
| blooms and billets can be processed into semi finished shapes such as tubes 384 |
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Term
|
Definition
| Decrease the length and increase the cross section |
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Term
|
Definition
| involves increasing the diameter of a material by compressing its length. Most widely used of all forging processes.- uses split dies that contain multiple positions or cavities. Forms heads on bolts and other fasteners. 395 |
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Term
|
Definition
| produce the bend geometry by simple three-point bending. Since the resulting angle is controlled by the bottoming position of the upper die, a single set of tooling can produce a range of bend geometries from 180 degrees through the included angle of the die and the pressure required to form the beds is the lowest of the there operations. 421 |
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Term
|
Definition
| shape low-strength metals such as lead, tin, zinc, and aluminum into products such as collapsible tubes for toothpaste etc. – used in impact extrusion with open and closed dies 411 |
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Term
|
Definition
| used to make angle bends up to 150 degrees in sheet metal under 1.5 mm thick. 418 |
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Term
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Definition
| the plastic deformation of metals about a linear axis with little or no change in the surface area. 417 |
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Term
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Definition
| (hold down pressure) primary variable for process adjustment once the process has been designed and the tooling manufactured – uses force and pressure 437. |
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Term
|
Definition
| shearing operations where the shear blades are closed, curved lines along the edges of a punch and die- the piece being punched out becomes the workpiece and any major burrs or undesirable features should be left on the remaining strip. 427 |
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Term
|
Definition
| 421- they contact and compress the full area within the tooling. |
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Term
|
Definition
| 440- fluid or rubber is used to transmit the pressure required to transmit the pressure required to expand a metal or tube outward against a split female mold or die. |
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Term
|
Definition
| 417- rubbing a smooth, hard object over the minute surface irregularities that are produced during the machining or shearing. |
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Term
|
Definition
| if bottoming die continue to move beyond the bottoming position the material between the upper and lower die is plastically deformed and the operation extends into _______. |
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Term
|
Definition
| or cold forming a family of processes in which slugs of material are squeezed into shaped die cavities to produce finished parts of precise shape and size. |
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Term
|
Definition
| used for making enlarged sections on the ends of rod or wirse such as the head of nauls bolt rivets or other fasteners |
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Term
|
Definition
| the dominant cold working process in terms of product tonnage. Sheets strips bars and rods are cold rolled into products that have smooth surfaces and accurate dimensions. |
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Term
|
Definition
| can be used to improve or alter the surfaces of metal products |
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Term
|
Definition
| piercing and blanking or other combinations of operations occur sequentially during a single stroke of the ram |
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Term
|
Definition
| 422- moving tool compresses the work piece against a stationary form. |
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Term
|
Definition
| a punch and die operation used to separate a stamping or other product from a strip of stock |
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Term
|
Definition
| When the depth is greater than the diameter |
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Term
|
Definition
| Basic component of a piercing and blanking die set |
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Term
|
Definition
| 428- a modified shearing operation that is used to blank shapes from low strength material such as rubber fiver or cloth |
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Term
|
Definition
| 438- rib-like projections and matching grooves in the die and blank holder. |
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Term
|
Definition
| generally employed with finite-length feedstock |
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Term
|
Definition
| continuous feedstock is inserted into a grooved wheel and is driven by surface friction into a chamber created by a mating die segment |
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Term
|
Definition
| if the pushing force could be applied to the periphery of the feedstock rather than the back continuous feedstock could be converted into continuous product and the process could become one of _________ |
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Term
|
Definition
| 422- work piece is clamped against a bending form and the entire assembly is rotated to draw the work piece under a stationary pressure tool. |
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Term
|
Definition
| Key variables in the deep drawing process include the blank diameter and the punch diameter,which combine to determine this. |
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Term
|
Definition
| 445- the combination of tension and compress |
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Term
|
Definition
| the metal is deposited onto a preshaped form or mandrel by plating |
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Term
|
Definition
| 444- a conductive solid is positioned within a cylinder of conductive material around the cylinder or adjacent to a flat sheet |
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Term
|
Definition
| 444- is a press working process in which raised lettering or other designs are impressed in sheet material |
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Term
|
Definition
|
|
Term
|
Definition
| The shank on the "blind" side expands to form a retaining head when a heated tool is touched against the exposed segment and detonates the charge. |
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Term
|
Definition
| 771- produce thin, flat gears of good quality. |
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Term
|
Definition
| 424- can be rolled on sheet metal in essentially the same manner as seams |
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Term
|
Definition
| 433- must be designed for the specific condition of material reduction and friction |
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Term
|
Definition
| 435- a modification of the spinning process in which each element of the blank maintains in distance fro the axis of oration. |
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Term
|
Definition
| if multiple bens are made with a single die |
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Term
|
Definition
| a quick and economical means of evaluating the severity of deformation in a formed part |
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Term
|
Definition
| were first used to shape low strength metals such as lead tin zinc and aluminum into products such as collapsible tubes for toothpaste medication and other creams small can for shielding electronic components; zinc cases for flashlight batteries and larger cans for food and beverages. The process is often used in combination with cold heading. |
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Term
|
Definition
| developed by the aircraft industry where the production of small numbers of duplicate parts clearly favors the low cost of tooling. Can be used on aluminum sheet up to 3mm thick and on stainless steel up to 1.4mm. |
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Term
|
Definition
| 443- a number of methods have been developed to form metals through the application of large amounts of energy in a very short time interval (high strain rate) |
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Term
|
Definition
| 437 or blank holder force if the force or pressure is to low wrinkling may occur at the start of the stroke. If it is too high there is too much restraint and the descending punk will simply tear the disk or some portion of the already formed cup wall. |
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Term
|
Definition
| 416 – a cold working process that is used to plastically form recessed cavities in a work piece |
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Term
|
Definition
| produce motion as the result of piston movement and longer or variable length strokes can be programmed within the limitation of the cylinder. |
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Term
|
Definition
| high pressure fluid surrounds the work piece and applies the force necessary to extrude it through the die |
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Term
|
Definition
| or cold extrusion been applied to the forming of mild steel part this process is often used in combination with cold heading. |
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Term
|
Definition
| 429- two alignment guideposts. |
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Term
|
Definition
| name given to a process that thins the walls of drawn cylinder by passing in between a punch a die whose separations is less than the original wall thickness |
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Term
|
Definition
| A foot operated press that are generally used for very light work such as shearing small sheets. |
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Term
|
Definition
| a piercing operation that forms either a line cut (slit) or an actual hole in the metal |
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Term
|
Definition
| generally used for bottom bending and coining while hydraulic presses are preferred for air bending |
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Term
|
Definition
| (R) smallest bend radius that can be formed without metal cracking |
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Term
|
Definition
| 429-or suppress dies wide variety of standardized self contained die sets |
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Term
|
Definition
| 449-multiple die sets are mounted side by side along the simultaneously in single machine. |
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Term
|
Definition
| 418- location that is neither stretched nor compressed. |
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Term
|
Definition
| 428- a contour is cut by producing a series of overlapping slits or notches |
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Term
|
Definition
| 428- is used to remove segments from along the edge of an existing product. The edge of the strip or blank forms part of the punch out perimeter. |
|
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Term
|
Definition
| 415- rivet is usually headed in a single squeezing action, although the heading punch may also rotate so as to to shape the head in a progress manner. |
|
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Term
|
Definition
| an be adapted to produce thin, spray-formed products |
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|
Term
| Parallel-Plate Hydroforming |
|
Definition
| 440- extends the process to the simultaneous production of upper and lower contours. |
|
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Term
|
Definition
| 417- mechanical working of surfaces by repeated blows of impelled shot or a round-nose tool. |
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Term
|
Definition
| consists of piercing a large number of closely spaced holes. |
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Term
|
Definition
| Shearing operation where the shear blades and closed, curved, lines along the edges of a punch and die, the punch-out is the scrap and the remaining strip is the workpiece. |
|
|
Term
|
Definition
| 440- extends the process to the simultaneous production of upper and lower contours. |
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Term
|
Definition
| A sudden application of high pressure gas propels upper die onto the workpiece. |
|
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Term
|
Definition
| a pull-up pin is used to expand a tubular shank. |
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Term
|
Definition
| 422-utilizes a downward descending bend die which pushes into the center of material that is supported on either side by wing dies. |
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Term
|
Definition
| (418) 19.3- mechanical or hydraulic presses with a long narrow bed and short, adjustable strokes. Make bends in heavy sheets. |
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|
Term
| Pressure Induced Ductility |
|
Definition
| (413) 19.2- relatively brittle materials such as molybdenum, beryllium, tungsten, and various inter-metallic compounds can be plastically deformed without fracture. These low ductility metals become formable. |
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|
Term
| Pressure-to-Pressure Extrusion |
|
Definition
| (413) 19.2-the product emerges from one pressurized chamber into a second high pressure chamber. The metal deformation is preformed into a highly compressed environment. |
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|
Term
|
Definition
| (431) 19.4- 2 or more sets of punches and dies mounted in tandem. |
|
|
Term
|
Definition
| (428) 19.4-basic component of a piercing and blanking die set. Part that retracts. |
|
|
Term
|
Definition
| (428) 19.4- also shear angle. It is an angle between punch and work piece. |
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Term
|
Definition
| (415) 19.2- an expanded head is formed on the shank end of a fastener to permanently join sheets or plates of material. |
|
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Term
|
Definition
| (422) 19.3- continuous form of 3 point bending where plates, sheets, beams, pipe, and even rolled shapes and extrusions are bent to a desired curvature. |
|
|
Term
|
Definition
| (414) 19.2- thin-walled cylinders can be produced from thicker-wall material. |
|
|
Term
|
Definition
| (423) 19.3- progressive bending of metal strip as it passes through a series of forming rolls and speeds up to 80m/min. |
|
|
Term
|
Definition
| (424) 19.3- also roller leveling. Subjects the material to a series of reverse bends to straighten the material. |
|
|
Term
|
Definition
| (417) 19.2- improves the size and finish of internal and external cylindrical and conical surfaces. |
|
|
Term
|
Definition
| (439) 19.5- also Guerin process. Rubber at the proper consistency and when it is totally confined, acts as a fluid and transmits pressure uniformly in all directions. |
|
|
Term
|
Definition
| 19.3- bending operation that can be used to join the ends of sheet metal in some form of mechanical interlock. |
|
|
Term
|
Definition
| (437) 19.5- when the depth of the product is less than its diameter. |
|
|
Term
|
Definition
| (428) 19.4- finishing operation in which a small amount of metal is sheared away from the edge of an already blanked part. |
|
|
Term
|
Definition
| (436) 19.5- metal forming shearing. |
|
|
Term
|
Definition
| (435) 19.5- spinning process in which each element of the blank maintains its distance from the axis of rotation. |
|
|
Term
|
Definition
| (424) 19.4- mechanical cutting of materials without the formation of chips or the use of burning or melting. |
|
|
Term
|
Definition
| (422) 19.3- material to be shaped or bent. |
|
|
Term
|
Definition
| 19.5- family of processes in which a rubber bladder backed by oil pressure, or pockets of pressurized liquid replace either the solid punch or female die of the traditional tool set. |
|
|
Term
|
Definition
| (414) 19.2- squeezing all or selected regions of forgings, ductile castings, or powder metallurgy products, to achieve a prescribed thickness or enhanced dimensional precision. |
|
|
Term
|
Definition
| (427) 19.4- length wise shearing process used to cut rolls of sheet metal into several rolls of narrower width. |
|
|
Term
|
Definition
| (444) 19.5- large capacitor bank is discharged in electromagnetic forming. |
|
|
Term
|
Definition
| 19.5- cold forming operation where a rotating disk of sheet metal is progressively shaped over a mandrel to produce shapes. |
|
|
Term
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| (426) 19.4- way to shear metal along a straight line with a moving blade. |
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| (446) 19.6- injecting powdered material into a plasma torch. The particles melt and are propelled onto a mandrel to form the desired material. |
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| (415) 19.2- method of permanently joining parts together when a segment of one part protrudes through a hole in the other. |
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| (445) 19.5- quick economical means of evaluating the severity of deformation in a formed part. |
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| 19.5- means of producing large sheet metal parts in low or limited quantities. |
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| (424) 19.3- material is gripped mechanically and stretched beyond the elastic limit to produce the desired flatness. |
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| 19.3- when the axes of deformation are ot linear, or are not independent. |
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| 19.2- separated parts due to shearing. |
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| attached above the die to keep the strip material from ascending with the retracting punch. |
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| (429) 19.4- standardized, self-contained die sets that can often be assembled and combined on the bed of a press to pierce or blank large parts. |
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| 19.5- producing materials with ultrafine-grain-size, and performing the deformation at low strain rates and elevated temperatures, elongation can exceed 100% and may reach 3000%. |
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| uses external hammering to reduce the diameter, taper, or point round bars or tubes. (also known as rotary _____ or radial forging) |
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| 19.2- cold-rolling operation that is an alternative to the cutting of threads. |
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| (432) 19.4-the individual dies in the process that the individual parts are mechanically moved from die to die. |
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| (449) 19.7- have long moving slide tat enables multiple operations to be performed simultaneously in a single machine. |
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| 19.4- shearing-type operation. |
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| (423) 19.3- bending of a tube or pipe. |
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| 19.5- produces high-quality tubing where the product requires the smooth surfaces, thin walls, accurate dimensions, and added strength. |
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| (442) 19.5- a process for manufacturing strong, lightweight, one-piece automotive components, which frequently replace an assembly of welded stampings. |
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| (433) 19.5- thich-walled tubes and those less than .5inches in diameter are often drawn without a mandrel in the process. |
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| (432) 19.4-specified to produce many holes of varying sizes and shapes are to be placed in sheet components. |
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| (410) 19.2- high-speed operation enabling a wide variety of relatively complex parts to be formed to close tolerances. |
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| (434) 19.5- same process as bar drawing except that it involves smaller diameter material. |
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