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A forge is a type of hearth used for heating metals, or the workplace (smithy) where such a hearth is located. The forge is used by the smith to heat a piece of metal to a temperature where it becomes easier to shape by forging, or to the point where work hardening no longer occurs. The metal is transported to and from the forge using tongs, which are also used to hold the workpiece on the smithy's anvil while the smith works it with a hammer. Sometimes, such as when hardening steel or cooling the work so that it may be handled with bare hands, the workpiece is transported to the slack tub, which rapidly cools the workpiece in a large body of water. However, depending on the metal type, it may require an oil quench or a salt brine instead; many metals require more than plain water hardening. The slack tub also provides water to control the fire in the forge.
Forging is a manufacturing process involving the shaping of metal using localized compressive forces. The blows are delivered with a hammer or a die. Forging is often classified according to the temperature at which it is performed: cold forging, warm forging, or hot forging. For the latter two, the metal is heated, usually in a forge. Forged parts can range in weight from less than a kilogram to hundreds of metric tons. Forging has been done by smiths for millennia; the traditional products were kitchenware, hardware, hand tools, edged weapons, cymbals, and jewellery. Since the Industrial Revolution, forged parts are widely used in mechanisms and machines wherever a component requires high strength; such forgings usually require further processing to achieve a finished part. Today, forging is a major worldwide industry.
Metalworking is the process of working with metals to create individual parts, assemblies, or large-scale structures. The term covers a wide range of work from large ships and bridges to precise engine parts and delicate jewelry. It therefore includes a correspondingly wide range of skills, processes, and tools.
A beam is a structural element that primarily resists loads applied laterally to the beam's axis. Its mode of deflection is primarily by bending. The loads applied to the beam result in reaction forces at the beam's support points. The total effect of all the forces acting on the beam is to produce shear forces and bending moments within the beam, that in turn induce internal stresses, strains and deflections of the beam. Beams are characterized by their manner of support, profile, equilibrium conditions, length, and their material.
A die is a specialized tool used in manufacturing industries to cut or shape material mostly using a press. Like molds, dies are generally customized to the item they are used to create. Products made with dies range from simple paper clips to complex pieces used in advanced technology.
Knurling is a manufacturing process, typically conducted on a lathe, whereby a pattern of straight, angled or crossed lines is rolled into the material.
Sheet metal is metal formed by an industrial process into thin, flat pieces. Sheet metal is one of the fundamental forms used in metalworking, and it can be cut and bent into a variety of shapes. Countless everyday objects are fabricated from sheet metal. Thicknesses can vary significantly; extremely thin sheets are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate steel or "structural steel".
Shot peening is a cold working process used to produce a compressive residual stress layer and modify the mechanical properties of metals and composites. It entails striking a surface with shot with force sufficient to create plastic deformation.
Turning is a machining process in which a cutting tool, typically a non-rotary tool bit, describes a helix toolpath by moving more or less linearly while the workpiece rotates.
An I-beam, also known as H-beam, w-beam, universal beam (UB), rolled steel joist (RSJ), or double-T, is a beam with an I or H-shaped cross-section. The horizontal elements of the I are flanges, and the vertical element is the "web". I-beams are usually made of structural steel and are used in construction and civil engineering.
Punching is a forming process that uses a punch press to force a tool, called a punch, through the workpiece to create a hole via shearing. Punching is applicable to a wide variety of materials that come in sheet form, including sheet metal, paper, vulcanized fibre and some forms of plastic sheet. The punch often passes through the work into a die. A scrap slug from the hole is deposited into the die in the process. Depending on the material being punched this slug may be recycled and reused or discarded.
A girder is a support beam used in construction. It is the main horizontal support of a structure which supports smaller beams. Girders often have an I-beam cross section composed of two load-bearing flanges separated by a stabilizing web, but may also have a box shape, Z shape, or other forms. A girder is commonly used to build bridges.
In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness and to make the thickness uniform. The concept is similar to the rolling of dough. Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization temperature, then the process is known as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is known as cold rolling. In terms of usage, hot rolling processes more tonnage than any other manufacturing process, and cold rolling processes the most tonnage out of all cold working processes. Roll stands holding pairs of rolls are grouped together into rolling mills that can quickly process metal, typically steel, into products such as structural steel, bar stock, and rails. Most steel mills have rolling mill divisions that convert the semi-finished casting products into finished products.
A linear-motion bearing or linear slide is a bearing designed to provide free motion in one direction. There are many different types of linear motion bearings.
Bending is a manufacturing process that produces a V-shape, U-shape, or channel shape along a straight axis in ductile materials, most commonly sheet metal. Commonly used equipment include box and pan brakes, brake presses, and other specialized machine presses. Typical products that are made like this are boxes such as electrical enclosures and rectangular ductwork.
A punch is a hard metal rod with a narrow tip at one end and a broad flat "butt" at the other. When used, the narrower end is pointed against a target surface and the broad end is then struck with a hammer or mallet, causing the blunt force of the blow to be transmitted down the rod body and focused more sharply onto a small area. Typically, woodworkers use a ball-peen hammer to strike a punch.
A press brake is a machine pressing tool for bending sheet and plate material, most commonly sheet metal. It forms predetermined bends by clamping the workpiece between a matching punch and die.
Cold working or cold forming is any metalworking process in which metal is shaped below its recrystallization temperature, usually at the ambient temperature. Such processes are contrasted with hot working techniques like hot rolling, forging, welding, etc.
Section modulus is a geometric property for a given cross-section used in the design of beams or flexural members. Other geometric properties used in design include area for tension and shear, radius of gyration for compression, and moment of inertia and polar moment of inertia for stiffness. Any relationship between these properties is highly dependent on the shape in question. Equations for the section moduli of common shapes are given below. There are two types of section moduli, the elastic section modulus and the plastic section modulus. The section moduli of different profiles can also be found as numerical values for common profiles in tables listing properties of such.
Tube bending is any metal forming processes used to permanently form pipes or tubing. Tube bending may be form-bound or use freeform-bending procedures, and it may use heat supported or cold forming procedures.
References
- 1 2 Boljanovic, Vukota (2009). Metal Shaping Processes. New York: Industrial Press. p. 140.
- ↑ "Rolled Structural Shapes". Arntzen Rolling. Arntzen Corporation.
- ↑ How We Form Steel to Bend Metal Pipes and Tubing (roll forming)
- ↑ http://www.aasteelfab.com/structural_methods.php [ dead link ]