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Manufacturing Processes 2 Assignment

The document is an individual assignment for a Manufacturing Processes II course, detailing applications and advantages of forging, as well as comparisons between cold and hot working. It discusses the evolution of microstructure during hot forging, springback in sheet metal bending, and differences between bulk deformation and sheet metal processes. Additionally, it includes calculations for flow stress based on provided data.

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n02219827h
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5 views

Manufacturing Processes 2 Assignment

The document is an individual assignment for a Manufacturing Processes II course, detailing applications and advantages of forging, as well as comparisons between cold and hot working. It discusses the evolution of microstructure during hot forging, springback in sheet metal bending, and differences between bulk deformation and sheet metal processes. Additionally, it includes calculations for flow stress based on provided data.

Uploaded by

n02219827h
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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NATIONAL UNIVERSITY OF SCIENCE AND

TECHNOLOGY

FACULTY OF ENGINEERING

Department of Industrial and Manufacturing Engineering

Name: Langalenkosi M Ncube

Student Number: N02219827H

Course: Manufacturing Processes II

Course Code: 3213

Individual Assignment 1

Lecturer: K. Chinguwo

Due date: 15 February 2025

Question One
a. Three applications of forging
 Used for manufacturing automobile industry components such as
crankshafts, connecting rods, gears, and axles.
 Produces high-strength aerospace components like turbine blades,
landing gears, and structural parts.
 Used in making hand tools like wrenches, hammers, and pliers,
which require high durability.

b. Distinct advantages of forging


 Produces components with improved mechanical properties such as
strength, toughness, and fatigue resistance.
 The controlled deformation aligns the grain structure, enhancing
material properties.
 Produces products with a good surface finish especially cold
forging.
 The process helps minimize the material waste as the metal is
shaped through compression rather than removal of material.
 Reduced energy consumption.

c. Cold working

Advantages
 Produces a smoother surface finish due to the absence of scaling
and oxidation.
 Increases the strength of the material through strain hardening.
 Allows for more precise control of dimensions
Disadvantages
 Requires higher forces to deform the material which can lead to
increased energy consumption
 Can reduce the ductility of the material which can make it more
prone to cracking
 Can introduce residual stresses

Hot working
Advantages
 Requires lower forces to deform the material which reduces
energy consumption
 Reduces the introduction of residual stresses into the material
 Improves the formability of the material allowing for complex
shapes

Disadvantages
 Produces poor surface finish due to scaling and oxidation.
 Less dimensional control
 Reduces the strength of the material due to recrystallization.

d. Use lubricants during metal forming.

 Reduces heat buildup in tools and workpieces, preventing thermal


damage.
 Avoids adhesion of workpiece material to the dies, ensuring a
consistent finish
 Minimizes wear and tear on tools and dies, improving tool life due
to friction.

Question Two

a. The evolution of microstructure and material properties during an open


die hot forging operation.

Open die hot forging refines the microstructure and enhances mechanical
properties by deforming metal above its recrystallization temperature.
Initially, the material has a course, equiaxed grain structure with possible
defects like porosity and segregation.
During forging, grains elongate in the deformation direction, increasing
dislocation density and causing strain hardening. At high temperatures,
dynamic recovery and dynamic recrystallization occur, replacing
deformed grains with new, finer grains. If the material is held at high
temperatures after forging, static recrystallization further refines the
structure. The final microstructure consists of fine, equiaxed grains,
improving strength, toughness, and ductility while reducing defects.
Cooling rate impacts properties: slow cooling enhances ductility but
reduces strength, while rapid cooling preserves fine grains, increasing
strength and hardness. When performed on a hot work part with cold dies,
the barrelling effect is even more pronounced. This results from a higher
coefficient of friction typical in hot working and heat transfer at and near
the die surfaces, which cools the metal and increases its resistance to
deformation. The hotter metal in the middle of the part flows more
readily than the cooler metal at the ends.

b. Springback in sheet metal bending and methods used to compensate for


it.

When the bending pressure is removed at the end of the deformation


operation, elastic energy remains in the bent part, causing it to recover
partially toward its original shape. This elastic recovery is called
springback, defined as the increase in included angle of the bent part
relative to the included angle of the forming tool after the tool is
removed.

The amount of springback increases with modulus of elasticity E and


yield strength Y of the work metal. Compensation for springback can be
accomplished by several methods. Two common methods are
overbending and bottoming. In overbending, the punch angle and radius
are fabricated slightly smaller than the specified angle on the final part so
that the sheet metal springs back to the desired value. Bottoming involves
squeezing the part at the end of the stroke, thus plastically deforming it in
the bend region.

c. The difference between bulk deformation and sheet metal processes

Bulk deformation Sheet metal processes

Involves significant plastic Involves forming thin metal sheets


deformation of a workpiece, into desired shapes without
changing its shape and size with significant change in thickness.
large volume displacement
Thick workpieces, typically Thin sheets, plates, or foils.
billets, bars, or ingots.
High forces needed due to large Comparatively lower forces
volume deformation. required.
Forging, rolling, extrusion, and Bending, deep drawing, shearing,
drawing. punching, and stamping.

d. Given data
strength coefficient, K = 640 MPa
strain hardening exponent = 0.28
final true strain, E = 0.85
i. Now using the equation, flow stress
n
Y f =KE
Y f =640 ¿
Y f =¿ 611.5 MPa
ii. The average flow stress that the metal experienced during the
operation.

n
KE
Yf=
n+1

0.28
640(0.85)
Yf=
1+0.28

Y f =477.8 MPa

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