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Hot and Cold Working of Metals

This document discusses hot and cold working processes for metals. It explains that hot working involves heating metal above its recrystallization temperature to make it plastic and then forming it. This produces a fine, uniform crystal structure. Cold working is done below the recrystallization temperature and makes the metal harder but less ductile through work hardening. Rolling is the most common metal forming process and involves compressing metal between rolls to reduce thickness or change shape. Both hot and cold rolling affect the metal's grain structure.

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Vitthal Gawhale
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181 views20 pages

Hot and Cold Working of Metals

This document discusses hot and cold working processes for metals. It explains that hot working involves heating metal above its recrystallization temperature to make it plastic and then forming it. This produces a fine, uniform crystal structure. Cold working is done below the recrystallization temperature and makes the metal harder but less ductile through work hardening. Rolling is the most common metal forming process and involves compressing metal between rolls to reduce thickness or change shape. Both hot and cold rolling affect the metal's grain structure.

Uploaded by

Vitthal Gawhale
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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HOT AND COLD

WORKING OF METALS
INTRODUCTION

• Manufacturing companies producing metals and supply metals


in form of ingots which are obtained by casting liquid metal into
a square cross section.
– Slab (500-1800 mm wide and 50-300 mm thick)
– Billets (40 to 150 sq mm)
– Blooms (150 to 400 sq mm)
• Sometimes continuous casting methods are also used to cast
the liquid metal into slabs, billets or blooms.
• These shapes are further processed through hot rolling, forging
or extrusion, to produce materials in standard form such as
plates, sheets, rods, tubes and structural sections.
Hot working processes

Hot working (forming) involves heating the metal (above the material's
recrystallization temperature) to its "plastic" state.
• Metal decreases in strength. Grains are more easily distorted.
• New and smaller crystals form and grow when temperature is maintained.
• Fine crystal structure forms when the metal temperature is quickly dropped
below the recrystallization point.
• Produces uniform stress-free grain structure.
• Hot formed metal are typically stronger and tougher than similar shapes
produced by casting or machining operations.
• Temperature range for hot working
• Ferrous metals (Steels) 930°C to 1370°
• Copper ,brass and bronzes 590°C to 930°
• For aluminum and magnesium alloys 345°C to 480°
Recrystallization Temperatures
Cold working processes
 Cold working is done below the recrystallization temperature with no
appreciable recovery. The stress required to cause deformation is much
higher than hot working. Grains become deformed, elongated and distorted.
 There is increase in tensile strength, yield strength and hardness and a
decrease in Ductility. It is all because of work-hardening.
 Process is applicable only to ductile metals.
 Cold working induces residual stresses which call for subsequent heat-
treatment annealing) for relieving the stress.
 Since the process results in strain hardening and brittleness of the cold
worked metal, it has to be annealed. During deep drawing operations, done
in stages, annealing is carried out in between the drawings.
 Metals most adaptable to cold working include: mild steel (with low carbon
contents), per, brass, aluminum, stainless steel, duralumin and other copper
and aluminum alloys.
Effect of Cold working processes
Cold working processes
Hot working processes Cold working processes
1. Cold rolling
1. Rolling
2. Thread rolling
2. Forging
3. Cold forging or cold heading
3. Extrusion
4. Swaging and rotary swaging
4. Rotary tube piercing
5. Coining
5. Deep drawing and 6. Cold drawing
6. spinning 7. Wire drawing
8. Tube drawing
9. Cold extrusion
10. Impact extrusion
11. Hydrostatic extrusion
12. Cold bending and roll bending
SEQUENCE OF OPERATIONS FOR OBTAINING DIFFERENT SHAPES
Rolling
Change in grains structure in rolling
Salient points about rolling
• Rolling is the most extensively used metal forming process
and its share is roughly 90%
• The material to be rolled is drawn by means of friction into
the two revolving roll gap
• The compressive forces applied by the rolls reduce the
thickness of the material or changes its cross sectional area
• The geometry of the product depend on the contour of the
roll gap
• Roll materials are cast iron, cast steel and forged steel
because of high strength and wear resistance requirements
• Hot rolls are generally rough so that they can bite the work,
and cold rolls are ground and polished for good finish
• In rolling the crystals get elongated in the rolling direction. In cold
rolling crystal more or less retain the elongated shape but in hot
rolling they start reforming after coming out from the deformation
zone
• The peripheral velocity of rolls at entry exceeds that of the strip,
which is dragged in if the interface friction is high enough.
• In the deformation zone the thickness of the strip gets reduced and it
elongates. This increases the linear speed of the at the exit.
• Thus there exist a neutral point where roll speed and strip speeds are
equal. At this point the direction of the friction reverses.
• When the angle of contact  exceeds the friction angle  the rolls
cannot draw fresh strip
• Roll torque, power etc. increase with increase in roll work contact
length or roll radius
Pressure during rolling
Typical pressure variation along the
contact length in flat rolling. The peak
pressure is located at the neutral point.
The area beneath the curve, represents
roll force.

Friction in rolling: It depends on lubrication,


work material and also on the temperature. In
cold rolling the value of coefficient of friction
is around 0.1 and in warm working it is around
0.2. In hot rolling it is around 0.4. In hot
rolling sticking friction condition is also seen
and then friction coefficient is observed up to
0.7. In sticking the hot wok surface adheres to
roll and thus the central part of the strip
undergoes with a severe deformation.
Roll passes to get a Dia.12 mm rod from 100 x
100 mm billet
Roll configurations in rolling mills

• Two-high and three-high mills are generally


used for initial and intermediate passes during
hot rolling, while four-high and cluster mills
are used for final passes.
• Last two arrangements are preferred for cold
rolling because roll in these configurations are
supported by back-up rolls which minimize
the deflections and produce better tolerances.
Various Roll Configurations (a) Two-high (b) Three-high (c)
Four-high (d) Cluster mill (e) Tandem mill
Other deformation processes related to rolling

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