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Table 3.2 Forming processes

Process Description Image
Rolling The rolling process is a forming manufacturing method used to reduce the thickness or change the cross-sectional shape of a material by passing it
through pairs of rotating rolls. This process is commonly used with metals, but it can also be applied to plastics, ceramics, and other materials.
Rolling is widely used in various industries to produce sheets, plates, foils, rods, and other products with specific dimensions and properties.
There are different types of rolling processes, each suited for specific materials and applications. Here are some common types of rolling processes:
• Hot Rolling: In hot rolling, the material is heated above its recrystallization temperature (usually for metals) before being passed through the
rolls. This makes the material more malleable and reduces the force required for deformation. Hot rolling is used to produce items like sheet
metal, rails, and structural shapes.
• Cold Rolling: Cold rolling occurs at or near room temperature. It is used to produce materials with tighter dimensional tolerances and improved
surface finishes. Cold rolling is common for making thin sheets, strips, and foils used in applications like packaging and electronics.
• Flat Rolling: In flat rolling, the material is passed through the rolls in a flat orientation. It is used to reduce the thickness of materials like sheets (Source of image:
and plates. https://www.bellcliffe.com/types-of-rolling-
• Shape Rolling: Shape rolling is used to produce products with a specific cross-sectional shape, such as I-beams, rails, and structural angles. mill/)
• Ring Rolling: Ring rolling is used to produce seamless rings, often used for bearings, gears, and other circular components.
• Thread Rolling: Thread rolling is used to create threads on cylindrical parts. The material is pressed between cylindrical dies to form the thread
profile.
• Profile Rolling: Profile rolling is used to produce complex shapes with consistent cross-sections. It involves multiple pairs of rolls to gradually
shape the material.
The rolling process offers several advantages, including high productivity, efficient use of material, improved mechanical properties due to grain
structure refinement, and the ability to achieve precise dimensions and surface finishes. It is a cost-effective method for mass production of a wide
range of products.
However, rolling also has limitations. It may not be suitable for extremely thin or intricate shapes, and certain materials may require additional heat
treatment after rolling to achieve desired properties.
Overall, the rolling process plays a significant role in modern manufacturing, contributing to the production of various items that are essential to
everyday life and industrial applications.
Forging Forging is a metalworking process in which metal is shaped and deformed using compressive forces to create desired shapes or structures. It involves
the application of force, typically through the use of hammers, presses, or other machinery, to change the material's shape while it is in a solid
state. Forging is a critical method for producing strong, durable, and high-quality metal components used in a wide range of industries.
The forging process improves the mechanical properties of the metal, such as its strength, toughness, and resistance to fatigue. It also refines the
grain structure of the metal, making it less prone to defects and providing better material characteristics. As a result, forged components are often
preferred in applications where safety and reliability are essential.
There are several types of forging processes, each with its own characteristics:
• Open-Die Forging: Also known as smith forging, open-die forging involves shaping metal between flat dies with minimal constraint. The
material is repeatedly hammered or pressed until it takes the desired shape. Open-die forging is used for producing large, customized
components like shafts, bars, and blocks.
• Closed-Die Forging: In closed-die forging, the material is placed within shaped dies that contain cavities matching the desired final shape. The (Source of image:
dies are then pressed together to deform the metal into the desired form. This method is used to create more complex and intricate shapes https://www.mesinc.net/forging/)
with high precision.

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