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Braeden > L16 Intro To Bulk > Flashcards

L16 Intro To Bulk Flashcards

(65 cards)

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1
Q

4 Types of Bulk Deformation Types

A
  • Forging (Compressing)
  • Rolling (Rolling)
  • Extrusion (Pushing)
  • Drawing (Pulling)
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2
Q

What doesForging produce? Usually performed at what temperatures?

A
  • Production of discrete parts with a set of dies and compressive forces
  • Usually performed at elevated temperatures
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3
Q

Disadvantage of Forging?

A

Equipment and labour costs are high

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4
Q

What doesRolling produce?

A

Production of flat sheet and foil at high speeds with good surface finish

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5
Q

Rolling has “____” equipment costs and “____” labour costs

A
  • “High”

* “Low”

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6
Q

Why does Aluminum foil have a shiny side?

A

The shiny side is the side that is rolledIt doesnt make our food warmer or anything. Alan lolled at people who believed this

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7
Q

What does Extrusionproduce?

A

Production of long lengths of solid or hollow products with constant cross sections that may be cut to length

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8
Q

What doesDrawing produce?

A

Production of long rod, wire, and tubing with round or various cross section

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9
Q

Which is usuallythinner, Drawing or Extrusion?

A

Drawing is thinner with good surface finish

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10
Q

Advantages of Plastic Deformation?

A
  • Offers many structural and mechanical advantages over casting and machining
  • Plastic Deformation after casting reduces porosity
  • This grain refining process makes forged, drawn, extruded, and rolled products stronger than their castcounterparts
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11
Q

How does Plastic Deformation after casting reduce porosities?

A
  • By eliminating hollow pores

* Orients the grain in favourable directions

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12
Q

In Plastic Deformation, when secondary operations are needed what becomes an issue?

A

Residual Stress

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13
Q

In forging, grain directions follow the “_____” of a part which allows what?

A
  • In the direction of the contours of the part

* Allows the grains to be alligned along the direction in which they are the strongest

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14
Q

Definition of Forging

A

Forging denotes afamily of processes to make discrete parts in which plastic deformation takes place by compressive forces applied through various dies

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15
Q

3 types ofForging based on Temperature?These temperature rangesare different for different metals and are a function of melting point thereforewe define…?

A
  • Cold Forging (Room Temp)
  • Warm Forging (Warm Temp)
  • Hot Forging (Elevated Temp)
  • Define the homologous temperature T/Tm
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16
Q

What is the homologous temperature range of Cold Forging?

A
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17
Q

What is the homologous temperature range of WarmForging?

A

0.3-0.5Compromise between Cold and Hot

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18
Q

What is the homologous temperature range of HotForging?

A

> 0.6

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19
Q

Advantages of Cold Forging?

A
  • Higher dimensional accuracy (less shrinkage) Good surface finish
  • Because of less oxides
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20
Q

Pros and cons of Hot Forging

A
  • Lower dimensional accuracy
  • Poor surface finish
  • Less energy input for forming
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21
Q

T/Tm takeson what value for most metals? What temerature is this also known as?

A
  • T/Tm = 0.5

* Recrystallization Temperature

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22
Q

What is another name for Open Die Forging?

A

Upsetting (so pretty much Joel)

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23
Q

Briefly explainthe process ofOpen Die Forging? What kind of shapes is it generally for?

A
  • a piece is placed between 2 flat dies (Platens)
  • The pieces are reduced in height through compression
  • Simple Shapes
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24
Q

In forging, ideally the piece will deform “____“but in reality?

A
  • “Uniformly”

* Friction affects cause barrelling where a specimen developsa barrel shape

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25
What effect other than friction contributes to Barrelling in Open Die Forging? Especially in what situation?
* Heat Transfer | * Especially in forging a hot piece between cool dies
26
What reduces friction in Open Die Forging? 
* Lubrication  | * Vibration
27
Explain how Vibration reduces friction in Open Die Forging
When you vibrate things you have relative motion meaning kinematic friction which is less than static friction
28
Briefly describe Impression Die Forging
* The work piece acquires the shape of a die cavity while being deformed * In most cases, performed in many die cavities progressively shaping the piece from rough to fine * In some cases, the material flows outward forming flash
29
Dimensional Accuracy in Impression Die Forging is highly dependent on what? Range from?
* Highly dependent on process parameters | * Range from +/- 0.5-1% of size
30
What does Flash consist of and what is its importance?
* Consists of excess material formed during the forging process * The flash aids in allowing cavity to fully fill with material and create finer details in the forged piece
31
As forging operations progress, the flash forms and inhibits the material from flowing out of the die. This is due to?
Due to the relatively cool flash that is stronger than the remainder of the blank
32
After flash forms, what happens to the die pressure? This allows for?
* The die pressure increases substantially | * Allowing features in the die to be completely filled
33
What is Closed Die Forging? Why is accurate material amounts critical?
* Invovles forging without the formation of flash The "Wiggle Room" of the flash is no longer available and accurate material amounts are critical to avoid * surges in forging pressure * possible machine breakdown 
34
Why is Closed Die Forging better than Impression Die Forging?
* Closed Die Forging is typically more accurate | * Does not require as many finishing operations
35
What is Heading?
A miscellaneous forging operation that involves the upsetting of a single end of a blank creating a flat feature such as a bolt head (ex. bolts, screws)
36
What is Piercing?
* Creating an internal feature within a forging | * Usually has a high aspect ratio
37
An example of piercing other than holes? *Exam Question*Please look some up and message them to me, cause I think the first two I have are not the greatest examples
Work of Joel's Endless Research came up wtih * Seamless pipes * tubing * hexagonal cavity in bolt heads -->Due to my expertise in this area, i can conclude this one is the best example
38
What is Edging and Fullering?
* an intermediate forging process that Involves spreading material to different areas in a die for subsequent forging  * These are intermediate operations
39
Fullering is a "_____" in cross section and Edging is a "_____" in cross section
* Decrease | * Increase
40
What is Roll Forging? Why is it useful? 
* The cross sectional area is reduced through rolling dies | * Various grooves and features may be added creating a finished product 
41
Name Applications of Roll Forging
* Leaf Springs * Tapered Shafts * Kitchen Knives Note regular rolling is used to make flat plates
42
What is Coining? How high is the pressure compared to the flow stress and why is it important?
* Shaping in a completely closed capacity * Pressures as high as 5-6 times the flow stress of the material * Transfer fine detail and good surface quality to a part (ex. Minting Coins)
43
What is Skew Rolling? Example?
* Similar to roll forging except the dies are at angles to one another creating discrete parts * Ex. Ball Bearings
44
4 typical devices that do the forging operations (i.e. the compressing)
* Mechanical Press * Screw Press * Hydraulic Press * Hammers
45
What is a Mechanical Press?
* Use Mechanical components such as a crank or an eccentric cam to apply force * The machine is stroke limited and has a preset finishing position
46
Describe Screw Presses. How is Energy supplied? 
* Transmission of forging pressure through a vertical screw | * Energy is supplied via flywheel
47
Pros and cons of Screw Presses
* Good for small parts and for variable stroke velocities  | * Force limited
48
Describe Hydraulic Press
Have constant slow speed operation but are load limited
49
Describe Hammers. Advantage?
* Energy derived from potential energy of a ram * Energy Limited Good for hot forging due to high speeds of stroke * Allows less time to transfer heat
50
Amount of force used for equipment in forging, in increasing order 
Mechanical Press 107MN Note: Hammers are energy limited at 1100KJ
51
What are Forging Dies made out of and why are they made out of this material?
* Hardened Steels * Used to improve lift and create fine details * They also have a high hot hardness
52
What are the purpose of gutters in dies for a forging process?
They house the flash that leaks out
53
Why is it important to have lots of fillets in a die?
Instead of having sharp corners, fillets are used to avoid cracks, tears, and other defects
54
How are deep sections in forging dies created?
In multiple steps to avoid defects (too much material taken at a time would result in defects)
55
Name the three most common Defects in Forging
Buckling, Cold Shuts, Grain Flow Patterns
56
With respect to forging,  what causes buckling to occur?
Compressive stresses which causes an overlap
57
A buckled piece has what kind of bonding? (strong/weak)What is the solution to buckling? 
Weak bonding between the metal sectionsApply the right amount of material so it does not fold in on itself
58
What causes a cold shut? What is the solution?
* When material has to flow over a tight radius, it folds over itself. * Solution is to have appropriate radii in the dies
59
A cold shut reduces?
Fatigue Life
60
Grain flows can cause defects in forging. What orientation of the grains is most susceptible to attacks by contaminants and corrosion?
When the grains are perpendicular to the surface exposing end grains
61
When Grain flow patterns are aligned, this results in an isotropic/anisotropic material?What is the solution to this problem?
Anisotropic, which causes rough surfaces (easy to corrode). The solution is to rotate the blank while working it in the die
62
In an ideal forge situation, what are the two assumptions?
specimen undergoes uniform deformation forging platens (recall, these are the two plates that squish the blank) are frictionless and undergo uniaxial compression
63
In a realistic open die forge, what occurs as opposed to an ideal forging operation?
Barelling occurs due to friction between the blank and the platen, which causes uneven deformation
64
What are the two approximations used when a metal begins to yeild?This was a question on one of our first cards by the way
Von Mises (Maximum Energy Distortion Theory AKA Freiheit)Tresca Criterion (Maximum Shear Stress Theory)
65
What else should I know for this course?
Look at the calcs for Lecture 17, channel your inner machinest, "and be the best you, you can be" -Dr. Balinh Phan

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