1959 METAL FOUNDRY & FORMING PROCESS SHELL OIL INDUSTRIAL FILM 72242

the world's output of metal is more than 350 million tons a year almost all of it goes through a forming process metal forming means pressing squeezing all rolling metal into shape as opposed to machining forming depends on a basic property of metals plasticity the ability to change shape under pressure by forming ingots are changed into useable shapes at the same time the internal structure of the metal is altered the rim of the ingot on the left of the micrograph is made up of long columnar crystals in contrast to those further towards the center metal with this kind of structure tends to be brittle during forming the structure will become finer and more uniform the most important of all the metal forming processes is hot room this is a slapping mill it feeds a series of mill stands extending over a fifth of a mile which produce wide steel strip the slobbing mill reduces these 14 ton ingots into slabs about 8 inches thick as the rolls bite into the steel the crystals are all the time breaking down and forming again making the metal tougher and more resistant to fit the slapping mill is operated from a control room the pulpit purchase astride the rollin line the mill is in continuous operation day and night the chief operator and his assistants work eight-hour shifts the operator gauges the thickness of the slab to a fraction of an inch he sets the bite made by the work rules his controls direct the Rams which manipulates 7,000 tons of Steel every day edging passes reduce the slab to its proper width allow the slab to pass through the top rule is raised to nearly its full height the two rolls give this mill its name a too high reversing when the ingot has been rolled down to the slab eight inches thick it is sent to the shear the shears prop the slab into the correct lengths for the roughing mill a group of four high mill stands in series the slab is now under an inch thick and is ready for rolling industry the sixth and finishing mill does this as the strip passes each stand gets thinner that leaves the mill at 2,000 feet per minute over 20 miles per hour the strip hurtles down the run-out table cooled by jets of water as it goes at the end of the table it is wild on a coiler while one end is coiling 400 feet away the other end is still being reduced rolling has given the strip a fine regular grain structure its properties are better balanced it is tougher now and more ductile such hot rolled strip has many uses for example steel pipe or household gas and water is made from here it is being reheated in a tunnel furnace when it leaves the furnace the strip has been into a tube by forming roll further rolls press the edges of the tube tightly together for buck welding the tube is cut into lengths by a flying song and the section shoot away to a cooling rack as with steel most non-ferrous metals are hot roll this is a slab of copper just off red heat and covered with a thin layer of skate the slab passes between the bottom and little rolls and comes back between the middle and top because of its three rolls this is called a three high mill as a rule hot working does not need lubricants because the metal scale prevents sticking work rolls are cooled by water after the hot rolling metals often undergo another rolling process this time coal in cold rolling lubricants are very important lubricants are used to reduce friction they increase the reduction that can be made on each pass they carry away some of the heat produced and improve the surface finish in all metal forming processes the loading on bearings and gears is very heavy lubrication is critical rolling mills are generally lubricated by oil circulating in a large system complete with coolers filters and storage tanks a high proportion of steel strip is also cold roll using a dilute oil emotion here stripped from the hot mill is passing forward through three mill stands in succession to be reduced to a thirtieth of an inch a common thickness for car bodies after cold rolling strip has an extremely good surface finish but the regular grain structure it acquired and hot working has disappeared the grains have been lengthened in the direction of rolling the metal has become harder and stronger but less ductile sometimes this is satisfactory but sometimes the softness and ductility must be restored this is done by annealing in one process the metal is heated inside a container filled with an inert gas to prevent oxidation this is known as bright annealing here the heating is done by gas or oil and the whole process lasts for several hours annealing recrystallizes the metal and restores its regular grain structure cold rolling followed by bright annealing gives much the same result as hot rolling but with a better surface finish after annealing the strip can be worked more easily and is less liable to crack in this tube mill and oil emulsion lubricates and cools the strip as it is formed up into a tube the edges of the tube are welded between rotating copper electrodes rolling a continuous process produces material in bomb forging old as the blacksmith's train remains unsurpassed for making individual parts especially those events wicked shape or great size by hammer or press an almost finished article can be made directly from red-hot ingot or billet this a hundred and seventy tonne mass of steel is to be forged into a turbo generator shaft the 7,000 ton press squeezes the metal as much as eight inches at a stroke Oh a skilled Forge master can work even such enormous masses as this remarkably accurately though of course a good deal of machining will still be necessary drop forging used for small parts can reduce machining to a minimum the billet is place between shaped dives one on the anvil and one above on the hammer the impact of the upper die causes the metal to flow in such a way that its grain follows the shape of the die this gives the workpiece great toughness after the roughing up the crankshaft is foot between finishing dies sawdust helps to prevent the metal sticking when the flash has been cut off the crankshaft will require very little machining fine and regular grain structure is an important asset of forging the forging of railway car wheels has been greatly speeded up in recent years by linking many forming processes into a continuous sequence after rough forging the wheel needs a period of reheating before it is taken to be rolled out to its final diameter the dishing press forces the harbor to give the wheel extra rigidity forging from a solid billet is also used to make the very best seamless tube such as that used for oil drill pipe and high-pressure steam in rotary forging the to forging rolls are slightly inclined towards one another to break open the center of the ingot which flows over the piercer held on a mandrel a cool piercer point is used for each English the piercer produces a thick wall tube with medium length this has to be elongated and it's wall thickness reduced this is done in the plugged milk the thick-walled tube from the piercer is elongated by squeezing over the plug between the rolls much hot form tube is subsequently cold drawn and here lubrication again becomes essential this machine draws up to four hundred thousand feet of seamless tube a day large volumes of drawing lubricant are supplied to the dyes to reduce friction and to carry away the heat generated by the deformation of the methyl as the fume is drawn between the plug and die both the diameter and the wall thickness are reduced and the tube correspondingly lengthen for some small diameter tubes the plug is not mounted on a mandrel but is allowed to float in the tube the tube is pointed or swayed to allow it to pass through the die the drawing of wire is a similar cold process using dyes copper wire often starts as coils of rod produced by hot rolling to keep production continues successive coils are welded together the daya's the rods diameter and at the same time lengthen see each time a make a reduction of say 30% producing very high local pressures and temperatures this tends to cause heavy dye wear and dyes are therefore made of very hard materials such as tungsten carbide and diamond even so lubrication is of the utmost importance to keep dye wear to a minimum in modern continuous machines cap stands pull the wire through a number of dyes and successful for the finest gauges so wire may have to be drawn through 30 or $40 dyes of any required shape are also used in the extrusion process in extrusion metal is pushed through the die instead of being drawn extrusion is usually carried out hot this copper billet is just a tread heat the RAM applies a pressure of up to 1500 times such copper extrusions are widely used for making electrical gear extrusion produces an accurately shaped section with a good grain structure and a fine surface finish since the dyes are readily changed a wide variety of sections can be made in one extrusion press impact extrusion forms the hundreds of millions of tubes which today contain everything from glue to toothpaste here little slugs of aluminum are hit by a punch and flow over it to form at you pressing and deep drawing of sheet are used to produce a great variety of shapes steel strip up to 73 inches wide and form a whole car roof at a single pressing it is this ability of metal to flow which makes possible a multitude of manufacturing processes gear blanks are turned out in quantity by multiple forging presence wire is drawn down to a diameter of a thousandth of an inch or less aluminum can be rolled to paper thinness with perfect accuracy the knowledge and skill of methyl urges mechanical engineers production engineers lubrication specialists all combined to improve old methods and develop new ones all forming processes large and small depend on plasticity the fact that metal can be made to alter its shape under pressure it is on forming that the world relies for converting nearly all the metal it produces into shapes to serve its many needs you

Channel: PeriscopeFilm

Views: 478,948

Rating: 4.9223838 out of 5

Keywords: Periscope Film, Stock Footage, Metal (Visual Art Medium), Film (Media Genre), Foundry (Building Function), Royal Dutch Shell (Business Operation), Shell Oil Company (Business Operation), ironworks, iron worker, metal, ingots, Chemistry (Field Of Study), hot rolling, reversing mill, metal stamping, molten metal, United States Steel, industrial age, rotary forging, engineering, forming processes, auto parts, Steel (Material), plasticity

Id: aEatTMQsGtg

Length: 28min 20sec (1700 seconds)

Published: Sun May 10 2015

Reddit Comments

[u/fashoom]

The 50s-modern music at around the 17:00 mark is pretty cool, too. Nowadays nobody reaches for a dissonant classical soundtrack for educational videos.

[u/Mad_Jack_McMadd]

Safety equipment? What are ya, a pansy?

[u/sfo2]

“So what do you do for a living?”

“I’m a sawdust chucker. I chuck sawdust at red hot metal.”

[u/Eldias]

The collection that channel has of old war-era manufacturing videos is nothing short of amazing. I'm particularly fond of the Naval Gun Factory which was not a factory for making guns, but a factory for making factories for making guns.

[u/Big_Al_SixtySixtyOne]

No PPE is funny to watch.

That one guy throwing handfuls of sawdust in between the finishing press heads while the 200 lb piece of molten steel gets thrown around like a play toy is hilarious.

[u/rq-2]

So cool. Had no idea that the wheel forming process was so involved. Is the process more streamlined nowadays?

[u/inio]

What does the shot at 25:55 have to do with extrusion forming?

... other than going oddly well with the preceding shot ...

[u/fishbert]

Lubrication Specialist?
I bet they never caught shit from their coworkers. Nope, never.

[u/blackjesus75]

Not a pair of safety glasses in the entire factory lol.