Introduction to mechanical

Working: Products
 Terminologies based on the stage of production
Stage-I Stage-II
Semi-finished products Finished products

Processing Fabrication
Primary metal-working Secondary metal-working
Working Forming (or sheet forming)

Major Purposes:
 To achieve desired shape & size (geometry / profile and dimension).
 To achieve desired properties – physical, mechanical, electro-
chemical.
Application / Service
With the consideration of :
 Equipment capability.
 Process economy (cost and rate of production).
 Avoidance of equipment damage - die / tool /
platen.
 Process efficiency.
 Environmental regulations.
Ingot and its breakdown
Bloom, Billet, Slab – Plate, Sheet, Strip
 Ingot

An ingot is a material, usually metal, that is cast into a shape suitable for further
processing.
Grain structure an segregation within an ingot

mm
245
 Bloom and Billet

Bloom: First breakdown of the ingot, Square of slightly rectangular section:

150mm×150mm to 250mm×300mm.
Blooms are similar to billets except the cross-sectional area is greater than 36 sq in
(230 cm2).

Billet: A billet is a length of metal that has a round or square cross-section, with an area
less than 36 sq in (230 cm2). Billets are created directly via continuous casting or
extrusion or indirectly via hot-rolling an ingot.

Round
Square Billet Billet
 Slab

A slab is a length of metal that is rectangular in cross-section. It is

created directly from continuous casting or indirectly by rolling an
ingot. Thickness, 50 mm – 300 mm, width = 0.6 m to 1.5 m.
 Plate and Sheet

Plate: Finished or semi-finished product with a minimum thickness of 6.35 mm.

Width will be equal to the roll with length which can be handled or stripped.

Sheet: Thin section with maximum thickness of 6.35 mm.

 Strip and Foil

Strip: Maximum width of 600 mm with maximum thickness of 6.35mm.

Foil: Thin strip with maximum thickness of 1.5 mm and maximum width of 300 mm.
 Bar and Rod
Bar: Long, straight, symmetrical piece of uniform cross-section. May be round, square
or any other shape.

Rod: A bar having circular cross-section is called ‘Rod’

 Wire
Wire: Diameter less than 9.75 mm. Generally kept in coil form.
Applications
Construction
Construction
Transportation- Railways
Automobiles

Automotive Crash Testing

 Ship Building

Used to form both the hull (the skin that displaces the water) and the internal
bulkheads that stiffen it.
 Bending of plates for Ship Hull
Bending of steel plate for ship building Welded steel plate forming part of a
ship's hull

Joining different parts

 Line pipe for fuel transportation

Large diameter steel pipelines for oil and gas extraction and primary transport.
Reversing mill plate is converted to pipe in the U-O-E method or one of its variants.
Offshore marine structures

Courtesy: I M Martin, Corus RD&T

 Pressure vessel / Boiler

Pressure vessel: From hydroelectric power generation to reactor pressure vessel

 Defence

Armour- plate used to resist munitions, Submarines

Earth moving / ‘mining’ equipment – Yellow products

Q&T steel: From yellow goods (earth moving machinery) to sub-marine body
 Wear resistant plates, Crushers

Material hardness 400 BHN Material hardness 270 BHN

Wear resistant steels for bucket

Courtesy: I W Martin, Corus RD&T

Heavy Engineering and Machinery
 Energy – Renewable sources

New applications: Renewable source of energy – Wind farm towers, Solar panels
Aesthetics: Structures of pride