Manufacturing Process-1

Engr. M. Arslan Khan

Lecturer
UoL, Lahore Campus
Introduction

Engr. M. Arslan Khan

Education:

•MS (Design and Composite Structures)

HITEC University Taxila- 2017

•BS (Mechanical Engineering)

HITEC University Taxila- 2014

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Engr. M. Arslan Khan

Experiences:
•Lecturer (MED UoL, Lahore Campus)
September 2017- Till to Date
•Site Engineer (JV FWO & CSCE)
New BBIAI (2015-2017)
•Site Engineer (Descon at Port Qasim Karachi)
FFCP (6 Month)
•Research Assistant (ME Department)
HITEC University Taxila- (2014-2015)
•Internship (POF Wah Cantt.)
Pakistan Ordinance Factory- (2014-2015)

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1

Course Outline
• Introduction
• Forming & shaping processes and equipment
• Material removal,
• Cutting tools,
• Machining processes for producing various shapes,
• Extrusion and drawing,
• Sheet metal forming,

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1
Course Outline

• Forming & shaping plastics & composite materials,

• Joining process & equipment, s
• Solid state welding process,
• Metal casting process & equipment,
• Powder metallurgy,
•Surface treatment,
•Non-conventional machining process,
•Jigs & fixtures.

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1
Recommended Books

1. Fundamentals of Modern Manufacturing, By M. P.

Groover John Wiley & Sons
2. Manufacturing Engineering and Technology By Kalpakjian
Prentice Hall
3. Materials and Processes in Manufacturing By E. P
Degarmo Prentice Hall
4. Process and Materials of manufacture By F. A Lindberg.
5. Introduction to Manufacturing Process By John Aschey.
6. Manufacturing Process By B. H Amstead, P. F Ostwald.

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1
Deformation

There are two main categories of deformations:

1. Plastic Deformation
2. Elastic Deformation

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1

Forming:
Part V
Metal Forming and
Sheet Metalworking
Page No. 383

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1
Forming processes and equipment
Metal forming includes a large group of
manufacturing processes in which
plastic deformation is used to change
the shape of metal work pieces. By
using tools, usually die in metal
forming, which applies stresses.

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1

Classification
of metal
forming
operations.

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1
Bulk Deformation
(a)rolling,
(b) forging,
(c) extrusion,
(d) drawing.
Relative motion
in the operations
is indicated by v;
forces are
indicated by F.

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1
Sheet Metal Working
SMW are forming and cutting operations performed on metal
sheets, strips, and coils. The surface area-to volume ratio of the
starting metal is high.
Press-working is the term often applied to sheet metal
operations because the machines used to perform these
operations are presses (presses of various types are also used in
other manufacturing processes). Apart produced in a sheet
metal operation is often called a stamping.
Sheet metal operations are always performed as cold working
processes and are Usually, accomplished using a set of tools
called a punch and die.

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1
Sheet Metal Working
(a) bending,
(b) drawing,
(c) shearing:
(1) as punch first
contacts sheet,
(2) after cutting.
Force and relative
motion in these
operations are
indicated by F and v.

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1
Sheet Metal Working
MATERIAL BEHAVIOR IN METAL FORMING
• Flow Stress
• Average Flow Stress

TEMPERATURE IN METAL FORMING

• Cold Working
• Warm Working
• Hot Working
• Isothermal Forming

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1
Cold Working
Advantages
(1) Greater accuracy, meaning closer tolerances can be achieved.
(2) Better surface finish.
(3) Higher strength and hardness of the part due to strain hardening.
(4) Grain flow during deformation provides the opportunity for
desirable directional properties to be obtained in the resulting
product.
(5) No heating of the work is required, which saves on furnace and
fuel costs and permits higher production rates.
Disadvantages
(1) Higher forces and power are required to perform the operation
(2) Care must be taken to ensure that the surfaces of the starting
work piece are free of scale and dirt.
(3) Ductility and strain hardening of the work metal limit the amount
of forming that can be done to the part.
M. Arslan Khan (UoL, Lahore Campus)
Introduction

Manufacturing Process-1

Warm Working

Advantages
(1) Lower forces and power,
(2) More intricate work geometries possible,
(3) Need for annealing may be reduced or eliminated.

Disadvantages
Approximately similar with the Cold Working.

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1
Hot Working
Advantages
(1) The shape of the work part can be significantly altered,
(2) Lower forces and power are required to deform the metal,
(3) Metals that fracture in cold working can be hot formed,
(4) Strength properties are generally isotropic because of the
absence of the oriented grain structure typically created in
cold working,
(5) No strengthening of the part occurs from work hardening.
Disadvantages
(1) Lower dimensional accuracy,
(2) Higher total energy required,
(3) Work surface oxidation (scale),
(4) Poorer surface finish,
(5) Shorter tool life. M. Arslan Khan (UoL, Lahore Campus)
Introduction

Manufacturing Process-1
STRAIN RATE SENSITIVITY

FRICTION AND LUBRICATION IN METAL FORMING

If Coefficient of friction becomes large, a condition known as
sticking occurs.
Sticking in metalworking (sticking friction) is the tendency
for the two surfaces in relative motion to adhere to each
other rather than slide. M. Arslan Khan (UoL, Lahore Campus)
Manufacturing Process-1
Error Definitions

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1
Forming:
Part V
Bulk Deformation
Processes in metal
forming
Page No. 395
Chapter 19
Rolling
Flat Rolling and Its Analysis
Shape Rolling
Rolling Mills
M. Arslan Khan (UoL, Lahore Campus)
Forming

Manufacturing Process-1
Rolling
Flat Rolling and Its Analysis
Rolling is a deformation process in which the thickness of the work is
reduced by compressive forces exerted by two opposing rolls.

Flat Rolling

M. Arslan Khan (UoL, Lahore Campus)

Forming

Manufacturing Process-1

Draft

Reduction

Volume Ratio

Velocities Ratio

M. Arslan Khan (UoL, Lahore Campus)

Forming

Manufacturing Process-1
Shape Rolling
The work is deformed into a contoured cross section

M. Arslan Khan (UoL, Lahore Campus)

Forming

Manufacturing Process-1
ROLLING MILLS
2-High
Various rolling mill
configurations are
available to deal with
the variety of
applications and
technical problems in
the rolling process. 3-High
Cluster mill

Tandem Rolling Mill 4-high

M. Arslan Khan (UoL, Lahore Campus)
Forming

Manufacturing Process-1
OTHER DEFORMATION PROCESSES
RELATED TO ROLLING
The operations include thread rolling, ring rolling, gear
rolling, and roll piercing.

M. Arslan Khan (UoL, Lahore Campus)

Forming

Manufacturing Process-1

M. Arslan Khan (UoL, Lahore Campus)

Forming

Manufacturing Process-1

Roll piercing:
(a) formation of internal stresses
and cavity by compression of
cylindrical part
M. Arslan Khan (UoL, Lahore Campus)
Introduction

Manufacturing Process-1
Forging
 Open-Die Forging
 Impression-Die Forging
 Flash-less Forging
 Forging Hammers, Presses, and Dies
 Other Deformation Processes Related to Forging
Forging is a deformation process in which the work is
compressed between two dies, using either impact or gradual
pressure to form the part

A forging machine that applies an impact load is called a forging

hammer, while one that applies gradual pressure is called a
forging press.

M. Arslan Khan (UoL, Lahore Campus)

Forming

Manufacturing Process-1
Open Die Forging

M. Arslan Khan (UoL, Lahore Campus)

Forming

Manufacturing Process-1

M. Arslan Khan (UoL, Lahore Campus)

Forming

Manufacturing Process-1
Impression die forging

M. Arslan Khan (UoL, Lahore Campus)

Forming

Manufacturing Process-1
Flash less Forging

M. Arslan Khan (UoL, Lahore Campus)

Forming

Manufacturing Process-1
Flash less Forging

M. Arslan Khan (UoL, Lahore Campus)

Introduction

Manufacturing Process-1

M. Arslan Khan (UoL, Lahore Campus)