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Mechanical Working Processes

  • An Overview of Metal Forming and Forging Processes
  • Presented by: [Your Name]

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Advantages of Mechanical Working Processes

  • - Improves mechanical properties
  • - Enhances grain structure and strength
  • - Reduces porosity
  • - Provides better surface finish
  • - Suitable for mass production

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Difference Between Hot and Cold Working

  • Hot Working:
  • - Above recrystallization temp
  • - High ductility
  • - Poor surface finish
  • - High energy requirement

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  • Cold Working:
  • - Below recrystallization temp
  • - Higher strength
  • - Good surface finish
  • - Low energy requirement

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Advantages and Disadvantages of Hot and Cold Working

  • Hot Working:
  • + Improved ductility
  • + Refined grain structure
  • - High energy consumption
  • - Poor surface finish

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  • Cold Working:
  • + Better surface finish
  • + Improved strength
  • - Risk of cracking
  • - Higher force requirements

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Classification of Metal Forming Processes

  • - Compressive Stress: Forging, Rolling
  • - Tensile Stress: Wire Drawing
  • - Shear Stress: Blanking
  • - Combined Stress: Bending

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Questions

  • 1. What are the benefits of mechanical working?
  • 2. How does hot working differ from cold working?
  • 3. What are the key advantages and disadvantages?
  • 4. How are metal forming processes classified?

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Introduction to Forging

  • - Metal forming using compressive forces
  • - Enhances mechanical properties
  • - Used in aerospace, automotive, heavy industries

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Classification of Forging

  • - Open Die Forging
  • - Impression Die Forging
  • - Closed Die Forging
  • - Drop Forging
  • - Machine Forging
  • - Cold Forging

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Die Forging with Power Hammers

  • - Uses impact force to shape metal
  • - Requires high energy and precision dies
  • - Common for large-scale production

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Open Die Forging

  • - Metal deformed between flat dies
  • - Allows large component shaping
  • - Used for shafts, rings, bars

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Impression Die Forging

  • - Metal shaped in closed die set
  • - Produces precise, complex shapes
  • - Reduces machining needs

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Closed Die Forging

  • - Ensures uniform material distribution
  • - High production efficiency
  • - Common in automotive industry

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Drop Forging Hammers

  • - High-speed hammering process
  • - Used for precision forging
  • - Ensures strength and durability

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Considerations for Sound Forgings

  • - Proper material selection
  • - Correct die design
  • - Temperature control
  • - Post-forging heat treatment

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Forging Presses

  • - Hydraulic or mechanical presses
  • - Apply steady pressure
  • - Used for bulk production

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Machine Forging

  • - Automated forging process
  • - Ensures uniformity and precision
  • - Reduces defects and labor

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Forging Defects

  • - Incomplete filling of die cavities
  • - Cracks and laps
  • - Internal voids
  • - Surface defects due to improper heating

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Heat Treatment of Forgings

  • - Annealing: Reduces hardness
  • - Normalizing: Improves grain structure
  • - Hardening & Tempering: Enhances strength and toughness

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Cold Forging

  • - Performed at room temperature
  • - Used for small, precise parts
  • - Provides excellent surface finish

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Conclusion

  • - Enhances material properties
  • - Hot and cold working have distinct advantages
  • - Forging ensures durability and strength
  • - Proper process selection ensures quality

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Thank You

  • Questions?
  • Contact: [Your Email]