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Application of DLC Coatings in Metal Forming
Published in Peerawatt Nunthavarawong, Sanjay Mavinkere Rangappa, Suchart Siengchin, Kuniaki Dohda, Diamond-Like Carbon Coatings, 2023
T. Funazuka, Kuniaki Dohda, N. Mahayotsanun
Metal forming is the process of forming a material (work material) into the desired shape by applying sufficient force/pressure to deform it. In general, it is a processing method suitable for mass production because it requires less processing time, material loss, and relatively low energy consumption than other processing methods. Metal forming can be applied to large objects and is widely used in industrial production. Metal forming can be roughly classified into sheet forming and bulk forming processes, as illustrated in Figure 7.1. They can also be categorized by temperatures comparison between the workpiece’s melting temperature and deformation temperature as hot forming, warm forming, and cold forming.
Engineering design
Published in Alan Darbyshire, Charles Gibson, Mechanical Engineering, 2023
Alan Darbyshire, Charles Gibson
Solid forming processes include forging, rolling, pressing, drawing and extrusion. Materials formed in this way need to be ductile and malleable. Some materials such as copper and to a lesser extent steel may be formed in the cold state and are said to have been ‘cold worked’. The cold working of metals distorts the crystal lattice structure resulting in a reduced ductility and malleability and increased hardness. The phenomenon is known as ‘work hardness’, which may need to be removed by heat treatment before further cold working or material removal by machining.
Manufacturing Processes for Small Weapon Components
Published in Jose Martin Herrera Ramirez, Luis Adrian Zuñiga Aviles, Designing Small Weapons, 2022
Jose Martin Herrera Ramirez, Luis Adrian Zuñiga Aviles
Forming encompasses a variety of processes, such as rolling, forging, extrusion, stamping, cutting, bending, and drawing. Among them, forging, extrusion, and stamping are widely used in the manufacture of weapon components.
High-temperature wear behaviour of HVOF sprayed 65% (NiCrSiFeBC)−35% (WC–Co) coating
Published in Surface Engineering, 2020
Gagandeep Singh, Manpreet Kaur
The hot forming operations require relatively expensive tooling. The hardness and toughness of the dies must be adequate enough to withstand the changes in pressures and temperatures during their operation. Among different die materials, the chromium-based hot forming die steels, such as AISI H11 and AISI H13 are the most popular die materials used due to their ability to retain their hardness at elevated temperatures. But these die materials suffer failure due to wear and mechanical fatigue. The metal forming industries suffer heavy economic losses due to bad tribological practices. According to the reports of various researchers, the economic losses resulting from friction and wear are estimated to total 1–2% of the Gross Domestic Product [2]. The control of wear and friction is very significant to increase life and performance of tool-workpiece materials. Because of limited research in the field of high-temperature wear and friction, there is a need to develop and analyse more novel surface coatings which can reduce the friction coefficients, improve wear resistance and have the potential for use in high-temperature applications. Different surface coating techniques, namely weld overlay coatings; thermal spray and chemical and physical vapour deposition, etc had shown promise in improving wear resistance and service life of hot forming dies [3,4].
Classification and selection of sheet forming processes with machine learning
Published in International Journal of Computer Integrated Manufacturing, 2018
Elia Hamouche, Evripides G. Loukaides
Metal sheet forming is the process of transforming flat metal sheets to desired 3D geometries through mechanical means. In these processes, the sheet is reshaped without adding or removing material, and its mass remains unchanged. The material undergoes plastic strains to achieve the transformation. These often result in more uniform mechanical characteristics of the final workpiece when compared to contemporary processes such as machining and additive processes (Lange 1985). Sheet metal is used heavily in major industries such as the automotive and aerospace sectors. Example parts include car and lorry bodies, building roofs, engine covers, aeroplane fuselages and wings. Various processes are used to form rolled sheet metal using tools such as dies, rollers and jigs. Common processes include deep drawing, bending, stretch forming and roll forming (Swift and Booker 2003).
Cold deformation of dezincification resistant yellow brass for plumbing applications
Published in Materials and Manufacturing Processes, 2018
S. Sivasankaran, Abdulaziz S. Alaboodi, Fahad Al-Mufadi
High malleability with more corrosion resistance is the prime requirements for the plumbing parts used in water components, fixtures in manufacturing industries and forged parts.[123] It can be achieved from copper-based alloys economically.[4,5] Among several copper-based alloys, dezincification-resistant (DZR) brass called yellow brass is having excellent properties in machinability, forge ability, formability, rolling, and brazing; and which is available commercially at a lower price. This brass (Cu-35% Zn) is having a single α-phase copper alloy in which the incorporation of zinc enhances the strength of major solvent copper by solid solution strengthening mechanism.[678] Because the maximum solid solubility of zinc at room temperature is 37% and hence it produces the single-phase α-Cu crystal structure. The application of yellow brass in plumbing parts is usually fabricated by mechanical compression to a certain amount of plastic deformation at room temperature. Nowadays, all the manufacturing industries are focusing on fabricating the parts of low cost in which cold forming process is an alternative one. Further, cold forming process produces the parts with a good surface finish and net shape.[9101112] During room temperature, mechanical compression using hydraulic machine, proper strain rate (change of deformation per unit time) and the amount of deformation is playing a major role. The fitting parts are frequently showing some damages such as micro-crack/voids due to more amount of deformation and high value of strain rate (SR) during cold working.[13] This yellow brass is having low stacking fault energy which produces more shear band and twinning during room temperature deformation and hence, it is being used in most of the plumbing/fitting parts (locks, keys, door knobs, door locking mechanisms, bathroom fittings, zippers on the clothes and bags, etc …).[141516]