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Manufactoring > Metal forming > Flashcards

Metal forming Flashcards

1
Q

what are the basikc deformation processes for metal

A

rolling
forging
extrusion
drawing

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2
Q

what temperature is cold working preformed at

A

Ambient tempurature

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3
Q

what are the advantages of cold working

A

greater accuracy
close tolerances
better surface finish
higher strength and hardess
grain flow allows desirable directional properites
no heating equired
may eliminate secondary operations

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4
Q

disadvantages of cold working

A

high force/power required
starting workpeice must be free of scale/dirt
ductility/strain hardening limit amout of forming that can be completed
anneling may be required for further deformation

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5
Q

at what tempuratures is hot working preformed

A

above the recrystaization tempurature

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6
Q

what is the recrystalization tempurature

A

typically 50% of melting pointy in kelvin scale
a tempuratre where no strain hardening occurs and new grains areformed with mmo strain

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7
Q

what are the advantages of hot working

A

shape can be altered significantly
low force/power required
metals that cant handle cold work can be hot worked
strength properties are generally non directional
no work hardening occurs

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8
Q

disadvanages of hot working

A

lower dimensional accuracy
high energy required
work surface has oxidation/scale
poor surface finish
shorter tool life

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9
Q

at what tempuratures is warm working preformed

A

preformed above the amdient tempuare but below the recrystalization

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10
Q

what are the advantages of warm working

A

lower force/power then cold working
more intricate geometry possible
need for anneling may be reduced/eliminated

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11
Q

what is rolling

A

a processes in which the thicknessb of the work is reduced by compressive forces
most rolling is hpot rolling due to the large amount of deformation required
cold rolling can be preformed in the final stages of rolling

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12
Q

what is forging

A

a deformation processes in which the the work is pressed between 2 dies

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13
Q

forging facts

A

most forging is preformed hot
cold forging is used for certian products

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14
Q

what is the difference between a forge hammer an a forging press

A

forging hammer uses impact loads
forging press applies gradual pressure

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15
Q

what are the 3 types of forging operations

A

open die forging
impression die forging
flashless forging

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16
Q

what is open die forging

A

material is compressed between 2 flat dies
allows material to flow out in the x direction
creates simple shapes

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17
Q

what is impression die forging

A

preformed with dies that contain negive of desired shape
flash is formed as the metal nears its final position

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18
Q

impresson die forging facts

A

several steps required
not capable of close tolerances
seprate cavities required for each step

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19
Q

advantages of forging over maching

A

highe production rates
conservation of metal
greater part strength
favorable grain orrientation

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20
Q

what is flashless forging

A

metal being foorced into a completly enclosed die caviity
no flash is formed

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21
Q

what is important when it comes to flashless forging

A

material volume must equal die cavity volume

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22
Q

what is coining

A

special application of flashless forging
fine details are impressed onto top and bottom surfaces of workpeice

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23
Q

what is upset forging

A

a cylindrical workpeice decreases in length but increases in diameter

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24
Q

what is a common use of upset forging

A

forming heads on nails/bolts

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25
Q

what is extrusion in metals

A

material is forced to flow through a die opening with the the cross section shape the same as the die opening

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26
Q

what are the 3 types of metal extrusion

A

direct
indirect
impact

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27
Q

what is direct extrusion

A

the material is fored through the die opening by the ram

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28
Q

what is the main problem with direct extrusion

A

the significant amount of friction between the material and the walls of the container

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29
Q

what is indirect extrusion

A

the die is mounted on a. hollow ram and ram forces the material into the ram

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30
Q

hot extrusion advantages

A

reduces ram force
increases ram speed
reduces grain flow characteristics

31
Q

what is impact extrusion

A

ram impacts the part at a high speed for a shot distanceas

32
Q

what is drawing

A

similar to extrusion but the metal is pulled through a die

33
Q

what are the 3 types of drawing

A

wire
bar
tube

34
Q

what are the advantages of drawing

A

close dimensional control
good surface finish
improved strength and hardness
economical for mas production

35
Q

what are the advantages of sheet metalworking

A

good dimensional accuracy
good surface finish
high strenghth
relitivly low cost with mass production

36
Q

what are the 4 types of sheet metalworking

A

cutting
bending
drawing
other forming

37
Q

what are the 4 types of cutting

A

shearing
blanking
punching
laser

38
Q

what are the 3 stages of cutting

A

plastic deformatiobn
penetration
fracturwe

39
Q

what is shearing

A

a sheet metal cutting operation along a straight line between 2 cutting edges

40
Q

what is blanking

A

cutting sheet metal along a closed outline where the fallen peice is desired peice

41
Q

what is the peice that is cut out dring blanking called

A

blank

42
Q

what is punching

A

similar to blanking but the peice cut is scrap

43
Q

what is cut off

A

seperating part with no excess waste

44
Q

what is parting

A

seperating a part with excess waste

45
Q

what is peircing

A

a punching operation in which a hole is cut out

46
Q

what is slotting

A

simillar to periceing but a rectangular hole is cut

47
Q

what uis notching

A

cutting a portion of metal from the edge of the sheet

48
Q

what i ssemi notching

A

cutting a portion from inside the sheet

49
Q

what is trimming

A

a cutting operation to remove excess metal from an established shape

50
Q

what is shaving

A

shearing opration wth very small clearences

51
Q

what is perforating

A

simeltanious punching operation

52
Q

what is laser cutting

A

cutting using a highly cioncentrated beam of light

53
Q

what is v bending

A

a punch looking like a v presses in to make a v shape

54
Q

what is edge bending

A

pressure is held to part of the peice while the rest is bent with pressure being added

55
Q

what are th esteps od the bending process

A

bend allowance
bending force
spring back

56
Q

what is the neutral axis

A

a theoretical lime that stays the same during the bend

57
Q

what is spring back

A

the elastic energy in the metal wanting to move back to original flat shape

58
Q

what are 2 ways to comensate for spring back

A

overbending
bottoming

59
Q

what some bending operations

A

hemming
seaming
curling

60
Q

what is the drawing process for sheet metal

A

pressure is applied evenly on the blanka press add more force to bring the peice down into a hole to create the shape

61
Q

hwat are sone common defects n drawn parts

A

wrinkling at flange
wrinking at wall
tearing
earing
surface scratches

62
Q

what is reverse drawing

A

a secondary drawing process where part is flipped over

63
Q

what is emosing

A

creates rassed letters or ridges

64
Q

what is lacing

A

a combination of cutting and bending

65
Q

what is the guerin process

A

uses a think rubber pad to form sheet over block

66
Q

what are some advantages of the Guerin process

A

low tool kcost
form block can be made out of alot of different products
rubber pad can be used on may different peices
process attractive in small quantity production

67
Q

what is the disadvantage of the guerin process

A

onlly relivily low forces can be applied

68
Q

whatv is hydroforming

A

similar to the Guerin process but the rubber pad is switched o wiyh hydraloc fluid

69
Q

what are the advantages of hydroformin

A

good for high production
setup can be used more then once
deeper draws can be achieved
uniform pressure creates uniform wall tickness and prevents thickness

70
Q

what is the disadvanteage of hydroforming

A

relitivly high tool cost

71
Q

what is strectch forming

A

metal stretched and symoltaniously bent

72
Q

what is roll bending

A

large metal sheets are formed into curved sections using rollers

73
Q

what is roll formming

A

continuios bending in which opposing rules produce long sections

74
Q

what is spinning

A

a method in which the material is clamped and rotated in which it is gradually shaped around a mandrel

Manufactoring (9 decks)

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