14. Worked Metal-Forming-Cum-Business Project

This chapter presents a metal-forming project using a business-oriented approach. The manufacture of L-beams is analyzed by three methods: (a) Method 1 (rolling, shearing, and bending), (b) Method 2 (extrusion and shearing) using a direct extrusion machine, and (c) Method 2 (extrusion and shearing) using an indirect extrusion machine. The process flow charts for the manufacturing methods are presented; the flow charts show the dimensions of the work after each step (operation). The complete analyses for all the three manufacturing methods are conducted, including the calculations for rolling force, rolling power, rolling times, rolling cost, shearing force, shearing cost, bending force, bending cost, extrusion force, extrusion power, and extrusion cost. The most economical metal-forming method has been recommended based on the economics of manufacturing. This chapter contains 5 diagrams and 2 tables.