Swaging-> Thread Rolling (E)

Question 1

SWAGING

Answer 1

Uses multiple dies that close on the part along radial paths. can be done with large machines or HAND TOOLS

Question 2

HYDRAULIC SWAGING TOOLS

Answer 2

Use a pumping action for deforming ferrous metals

Question 3

HAND SWAGING TOOLS

Answer 3

Oversized pair of pliers that uses a compound lever action to generate large forces between the jaws (dies)

Question 4

FERRULE

Answer 4

A metal ring or cap that strengthens the end of a cable and prevents it from splitting or wearing.

Question 5

INDUSTRIAL SCALE SWAGING

Answer 5

uses multiple dies that all move towards the center simultaneously

Question 6

Why is SWAGING used to produce RATCHET SOCKET WRENCH SETS?

Answer 6

superior strength is required but minimal metal is available to resist the loads

Question 7

SOCKETS of a RATCHET SOCKET WRENCH

Answer 7

hollow but suddenly transition from a hexagonal hole (to slip over the nut/bolt) to a square hole (to attach to the ratchet drive lug)

Question 8

Why should the SOCKET holes never be cut?

Answer 8

Cutting them would sever the grain flow and compromise strength

Question 9

How are holes created in SWAGING?

Answer 9

MANDRELS

Question 10

MANDREL

Answer 10

a metal tool around which other metal is formed, mirrors the internal cavity of the part

Question 11

What must happen to the metal used for SWAGING?

Answer 11

first, it must be OPEN DIE FORGED to create a WROUGHT structure. then it is formed into a tubular shape with internal and external dimensions slightly larger than the final product.

Question 12

ROTARY SWAGING

Answer 12

the process that allows long lengths of material to be SWAGED. A ring of cam followers is rotated while being driven inwards and outward.

Question 13

How are “cold hammer forged barrels” for long guns made?

Answer 13

ROTARY SWAGING

Question 14

How is a Philips head screwdriver made?

Answer 14

SWAGING, doesn’t need a MANDREL because it is solid, not hollow

Question 15

ROLL-FORGING

Answer 15

A manufacturing process in between rolling and forging. Discrete products can be created between rotating dies (rollers) with an evolving shape attached around their perimeter.

Question 16

SKEW ROLLING

Answer 16

An example of ROLL-FORGING used to make steel balls for use in bearings. Two conical rollers with helical grooves of semicircular cross-section are offset at an angle (skewed).

Question 17

ROLLING

Answer 17

A process that produces very long lengths of stock material using dies in the form of ROLLERS.

Question 18

CONTINUOUS CASTING

Answer 18

molten metal is formed into SLABS which then enters into the ROLLER stages which is a non-stop process

Question 19

PLATE/SHEET STOCK

Answer 19

material rolled using smooth and featureless rollers

Question 20

ROLLERS

Answer 20

crush the CAST STRUCTURE and turn it into a WROUGHT STRUCTURE, reduce thickness.

Question 21

HOT ROLLING

Answer 21

ROLLING done at temperatures above recrystallization to avoid microcracking.

Question 22

ADVANTAGE of ROLLING

Answer 22

it provides stock with forged-like strength, inexpensive, long pieces of stock

Question 23

ROLLING MILLS

Answer 23

facilities where ROLLING is performed. these buildings can be up to 1/4 miles long.

Question 24

Stages of ROLLING PROCESS

Answer 24

reheat furnace
roughing mill
coil box
tensioning
finishing mill
cooled and coiled

Question 25

HOT ROLLED PLATE or SHEET

Answer 25

the final result of rolling processing

Question 26

What is the difference between PLATE and SHEET material?

Answer 26

PLATE material must be stacked flat
SHEET material can be coiled

Question 27

MILL SCALE/BLACK IRON OXIDE

Answer 27

black/gray coloration that forms on the surface at elevated temperatures. it can be cleaned off during the ROLLING process, but it will reform if hot enough. it is somewhat protective of the underlying metal and will hinder corrosion.

Question 28

What are the additional processing steps that turn HOT ROLLED STEEL into COLD ROLLED STEEL

Answer 28

ANNEALING & PICKLING, TEMPER ROLLING

Question 29

ANNEALING

Answer 29

softening heat treatment of the hot rolled steel

Question 30

PICKLING

Answer 30

mill scale is removed

Question 31

TEMPER ROLLERS

Answer 31

reduce the thickness by a few thousandths of an inch at room temperature.

Question 32

advantage and disadvantage of COLD ROLLED STEEL

Answer 32

it is more refined, but more expensive

Question 33

SHAPE or PROFILE ROLLING

Answer 33

uses grooves rollers to create STRUCTURAL STOCK from cast “bloom”, but can include a variety of additional rollers of various sizes, shapes, and orientations to form the required cross-sections.

Question 34

ROLLING DEFECTS

Answer 34

wavy edges
zipper cracks in the center of the flat rolling
edge cracks
alligatoring

Question 35

How are ROLLING DEFECTS generally caused?

Answer 35

heating issues, too aggressive thickness reduction steps, or deficient rigidity/concentricity of the roller systems

Question 36

ALLIGATORING

Answer 36

ROLLING DEFECT where the end of the rolled product resembles the open jaws of an alligator. It is caused by the upper and lower surfaces of the material getting attached to the rollers.

Question 37

How do rolling mills avoid alligatoring?

Answer 37

it is standard practice to saw a foot or so off the ends of rolled product to remove the possibility of hidden alligator cracks.

Question 38

RING ROLLING

Answer 38

used to create large circular workpieces using rollers

Question 39

SPLINE ROLLING

Answer 39

done with linear style dies or with more traditional rollers similar to those in ROLL-FORGING.

Question 40

SPLINES

Answer 40

grooves used to concentrically attach shafts together for torque transmission, and require proper grain flow for strength

Question 41

BOLTS

Answer 41

critical for assembling structures and must be strong.

Question 42

HEADING or ORBITAL FORGING

Answer 42

used to create the heads of BOLTS and ensure proper grain flow.

Question 43

THREAD ROLLING

Answer 43

ROLLERS with helical grooving or LINEAR DIES with angled grooves create the threads of a bolt to be strong

Question 44

CUTTING THREADS

Answer 44

will always produce weak, smooth, sharp, precise threads, and will result in a major diameter EQUAL to the shank.

Question 45

ROLLED THREADS

Answer 45

very strong, more rounded, and result in a major diameter that is LARGER than the shank.

Question 46

PRECISION BOLTS

Answer 46

“best of both worlds” between ROLLED and CUT THREADS