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MEC322 > Metalworking Techniques > Flashcards

Metalworking Techniques Flashcards

(75 cards)

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1
Q

What are the main bulk deformation processes in metalworking?

A

Rolling, forging, extrusion, and wire/bar drawing

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2
Q

What are the initial forms of metal for bulk deformation

A

Cylindrical/rectangular billets/bars, slabs, and other basic 3d shapes

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3
Q

What temperature must the deformation process be done at to undergo significant shape change?

A

Hot temperatures

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4
Q

What temperature must the deformation process be done at to undergo strength increases during shape change?

A

Cold temperatures

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5
Q

What is a net shape process?

A

Very little material is lost during machining, and the parts require very little subsequent machining

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6
Q

Is bulk deformation a net shape process?

A

Yes

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7
Q

What is rolling?

A

A slab or plate of metal is squeeze between opposing rolls

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8
Q

What is forging?

A

Work is squeezed and shaped between opposing dies

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9
Q

What is extrusion?

A

Work is squeezed through a die opening, taking the shape of the opening

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10
Q

What is wire and bar drawing?

A

Diameter of wire or bar is reduced by pulling it through a die opening

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11
Q

What does rolling achieve?

A

Lengthening the slab, but only increasing the width by a bit

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12
Q

What is the most important metal working process?

A

Rolling

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13
Q

What is a two-high rolling mill?

A

One roller on each side of the material, rollers can be reversed

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14
Q

What is a three-high rolling mill?

A

3 rollers stacked, metal passes through one and passed through the next

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15
Q

What are back-up rolls?

A

Rollers placed above/below the main work rolls to prevent roll deflection

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16
Q

What is roll deflection?

A

When the rollers themselves are elastically deformed

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17
Q

What is a 4 high rolling mill?

A

2 back-ups, 2 work rollers

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18
Q

What is a cluster mill?

A

Multiple backing rolls supporting 2 main rolls

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19
Q

What is a tandem rolling mill?

A

Multiple rolling mills placed in sequence

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20
Q

What can rolling speeds of tandem systems reach?

A

40m/s

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21
Q

What is flat rolling?

A

Used to reduce thickness of a rectangular cross section

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22
Q

What is shape rolling?

A

Square cross section is formed into a shape (such as an I Beam)

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23
Q

What is sticking?

A

When the coefficient of friction between the roll and work surface is high (0.7), and the work surface adheres to the roll

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24
Q

What happens to the coefficient of friction of a material as the temperature increases?

A

Increases

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25
What is compensation?
The prevention of deformation of rolls by having the rolls start initially convex, deforming to flat
26
What is camber?
When a sheet displays a convex/concave curvature after being rolled
27
What is undercambering?
The metal sheet shows a convex curvature after being rolled
28
What is overcambering?
The metal sheet shows a concave curvature after being rolled
29
What is hot rolled plate?
Cast ingots being rolled on large reversing mills
30
What does hot rolling ingots achieve?
Coarse dendrite casts are broken down, defects and voids are healed, however surface finish is rough
31
What is cold rolled sheet?
The rolling of a hot rolled plate after cooling to thin the size
32
What thickness do cold rolled sheets end up at?
less than 1/4 inch
33
Why must hot rolled plates be cold rolled?
To improve surface finish, tolerance, and mechanical strength
34
What is the difference between grain size and shape in hot rolled and cold rolled plates?
Hot rolled grains are disorganized and smaller, cold rolled are longer and come in layers
35
How does shape rolling work?
Only certain sections of the work are rolled at a time
36
What is thread rolling?
How threads are formed on cylindrical parts, by rolling them between two dies
37
Are threads cold or hot rolled?
Cold, for higher tolerancing
38
What is the advantage to rolling threads rather than cutting?
Higher production rate, less material waste, threads are stronger, due to work hardening
39
What does ring rolling achieve?
Decreasing wall thickness, while increasing diameter
40
What rolling process does ring rolling use?
Hot rolling for large rings, cold for small
41
How are steel balls made?
Threaded rollers cutting a cylindrical bar
42
How are tubes rolled
A solid rod with a cavity in the middle that is exploited by using a mandrel to control the size of the hole while it is rolled between two opposing rollers
43
What is roll-forging?
Rolls are given shapes to create the wanted indentations in the work piece
44
What is the oldest metal forming process?
forging
45
What is forging?
The controlled plastic deformation of metal into a predefined shape by process of pressure/impacts
46
What are the advantages of forging?
Work hardening from the impacts
47
What is open-die forging?
Work is compressed between two flat dies
48
What is impression die forging?
The die contains an impression that is the shape of the work part
49
What is flashless forging?
The work part is completely constrained in the die
50
What is flash?
Flash is the excess metal that flows out between dies
51
What are the advantages of hot and cold forging?
Hot forging allows for significant deformation and increased ductility, cold forging has increased strength from strain hardening
52
What is another name for open die forging?
Upsetting/upset forging?
53
What type of forming is hand forging?
Open die
54
What happens to the flash in impression-die forging?
The flash is pushed out of the impression and trimmed, however the flash also contains the metal in the cavity while the metal is still being forged
55
How are complex shapes forged?
Through multiple forgings, where more features are introduced with each forge
56
What restrictions does flashless forging have?
The starting volume of the workpart must equal die cavity volume with close tolerance
57
What is swaging?
Rotating dies that forge a piece into a taper
58
What is the most forgeable metal?
Aluminum alloy
59
What is the least forgeable alloy?
Tungsten alloy
60
What are some forge defects?
Laps from web buckling, internal defects from oversized billets
61
What is web buckling?
The web of a part (thin piece connecting two parts) fails under excessive force
62
What are laps?
The web overlapping itself after buckling
63
What is a gravity drop hammer?
Hammer that applies energy from falling weight of a ram
64
What is a power drop hammer?
Hammer is forcibly accelerated
65
What is a press?
A machine that applies gradual pressure to accomplish compression operations
66
What is a mechanical press?
Uses motor to drive ram
67
What is a hydraulic press?
Uses hydraulic (fluid) piston to drive ram
68
What is a screw press?
Screw mechanism drives ram
69
What is extrusion?
Compression forming process where work metal is forced through a die opening to create a cross-sectional shape
70
What is forward/direct extrusion
The product emerges in the same direction as the movement of the ram
71
What is reverse/indirect extrusion
Product emerges from opposite direction of ram movement
72
What is the butt?
An extra piece at the end of an extrusion that cannot be forced through the opening
73
How are hollow shapes made from solid bars in direct extrusion?
The ram includes a prong to create the hollow shape
74
How does indirect extrusion work?
The billet is stored in a container, and the ram either pushes the material around it, or has a hole to allow material through
75
What is wire/bar drawing?
Extrusion but the work is pulled instead of pushed

MEC322 (8 decks)

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