Question.

Give three reasons why wrought metal (metal forming)

products generally have superior properties to equivalent casting
products.

Wrought iron is used in metal forming because of thermo-physical properties.

Wrought iron is a type of alloy with a very low carbon percentage such as
less than 0.08%. In a cast iron carbon percentage varies between 2 to 4
percent. Cast iron is useful in casting. Cast iron is used to melt and poured
into a mold and allowed to cool to form a product.

Wrought iron is highly malleable in comparison to cast iron. Amount of

carbon percentage play big role in a property of malleable. Malleable alloy
can be heated and then worked with tools. With the help of tool we can
change wrought iron to various shape. The main difference of metal forming
and Casting product is that, in metal forming microstructure of workpiece will
improve. Due to this mechanical properties of workpiece imrove. In casting
microstructure of material destroy when melting.

Metal forming have various properties over casting. Three of them given
below-

1. Better Mechanical properties

The nature of metal forming excludes the occurence of porosity,

shrinkage, cavities and cold pour issue. The mechanical properties of
the metal forming product can be improved by thermo-mechanical
treatment. Due to this, the grain size of the material is reduced, this cause
dislocation is shorter than the casting. The compact grain structure of metal
forming making it mechanically strong. Therefore is less need for expensive
alloys to attain high strength components. The tight grain structure offers
great wear resistance. Because of thermo-mechanical treatment the
resulting product will display higher yield and tensile strength along with
better ductility and toughness than casting product

2. Flow Stress- Flow stress is one of the main reason to have better
properties in metal forming. The stress required to sustain a certain
plastic strain on the material is called Flow stress. Flow stress affects
the ability of material to undergo deformation. Flow stress can be
determined form simple uniaxial tensile test, homogeneous
compression test, plane strain compression test or torsion test. Factors
such as strain rate, temperature, affect the flow stress of materials.
 3. Ductility - Ductility of material is said to be ability of material to
deform under tensile load. In other terms if ductility of material more, it
can be stretched more. Ductility is improved due to microstructure in
metal forming improve. But in case of casting when metal melted the
microstructure of material break down, this cause casting product show
poor ductility.

Question. Bulk deformation processes include rolling,

forging, extrusion and drawing. Describe each process.

1. Rolling-

Rolling is a compressive deformation process. Rolling process is used for

producing semi-finished products such as bars, sheets, plates. Rolling can be
carried out both in hot and cold conditions Rolling deformation process
consists of sheet passing between two rolls that revolve in opposite
directions. The space between the rolls is less than the thickness of the
sheet.

There are different type of Rolling Process-

Ring Rolling
Roll Piercing
Hot Rolling
Thread Rolling
Cold Rolling
Planetary Mill
 2.Forging

Forging is the plastic working of metal using compressive forces exerted by

power hammers or special forging machines. Various type of forging have
been developed.

The metal may be increasing its length and decreasing its cross section.
Metal Squeezed in closed impression dies to produce multidirectional flow
state of stress. In forging the work is primarily uniaxial or multiaxial
compression.

The most common forging processes are-

Open-die hammer

Impression-die drop forging

Press forging

Upset forging
 Roll forging

Swaging

3.Extrusion-

The extrusion process is like squeezing toothpaste out of a tube. Metal is

compressed and forced to flow through a suitably shaped die to form a
product with reduced but constant cross section. Metal will undergo triaxial
compression.
Hot extrusion is commonly employed. Lead, copper, aluminum, magnesium,
and alloys of these
metals are commonly extruded. Steels, stainless steels, and nickelbased
alloys are
difficult to extrude. (high yield strengths, welding with wall). Use phosphate
based and molten glass.
There are different type of Extrusion Process

Direct Extrusion
Indirect Extrusion
Cold Extrusion
Backward Cold Extrusion
Impact Extrusion
 Hydrostatic Extrusion

4.Drawing

In drawing the wire is subjected to tension only. But when it is in contact with
dies then a combination of tensile, compressive and shear stresses will be
there in that portion only.
Drawing is a cold working process to obtain wires from rods of bigger
diameters with the help of a die. This process is same as bar drawing except
that it involves smallerdiameter material.
In Drawing, the end of the rod is to be drawn is pointed. So that it freely
enters the die orifice and sticks out behind the die. For thin wire, the material
may be passed through a number of dies, receiving successive reductions in
diameter.

Question What is the main difference between hot working and

cold working? List at least two advantage and two disadvantage of
cold working.

Hot Working -
 Hot Working done above the recrystallization temperature. Above
recrystallization temperature, the metal becomes plastic and causes the
growth of grains. In hot working, the grains are broken up and refinement of
grain occurs. Metals possess little elasticity and a low load is required to
shape the metal as the strength and hardness decrease at elevated
temperatures. Due to the refinement of grains, mechanical properties such
as toughness, ductility, elongation and reduction in area are improved. The
power required to finish the part ingot is less. Hot working can be used on
most of the metals because it is a rapid and economical process. By hot
working porosity of the steel ingot can be eliminated to a greater extent.

Cold Working
Cold working is the plastic deformation of metals below their recrystallization
temperature.
It is generally performed at room temperature.

Advantage of cold working-

1. No heating is required.
2. Better surface finish is obtained.
3. Superior dimension control.
4. Better reproducibility and interchangeability of parts.
5. Improved strength properties.
6. Directional properties can be imparted.
7. Contamination problems are minimized.

Disadvantage of cold working-

1. Higher forces are required for deformation.
2. Heavier and more powerful equipment is required.
3. Less ductility is available.
4. Metal surfaces must be clean and scale-free.
5. Strain hardening occurs.
6. Imparted directional properties may be detrimental.
7. May produce undesirable residual stresses.