FABTECH College of Engineering and Research, Sangola

UNIT 6

SECTION II UNIT 6 Introduction to forming process, classification of forming processes.

Forming Process: Metal Forming : A process in which the component shapes are made by plastic deformation. These processes are classified as per the type of force that is applied for carrying out the process. For Example: Forging & Extrusion uses compressive process .hence known as compressive forming process. The primary products which are either used as a finished product or used as a raw material for other processes For Example Rolled Products: Bars, Angle sections, beams, channels, sheets, plates, rail, rail wheels, strips, Roofing sheets etc. Drawn Products: tubes & wires Forged Products: shaft, crank shaft, gear blank, gears, Auto components etc. Extruded Products: Industrial components: Pressure vessels, pipes Sheet Metal Components: Auto bodies, utensils etc. Flow/ Roto Forming component : Ultra thin metallic tubes conical component & metallic Vessels

Classification of Forming processes:1. Rolling process a) b) c) d) e) 2. Forging Process a) b) c) d) e) 3. Extrusion Processes Open die forging Impression die forging Closed die forging Upset forging Rotary forging a) b) c) d) Direct Extrusion Indirect Extrusion Hydrostatic Extrusion Continuous Extrusion Longitudinal Transverse Axial Roll Forging Die Rolling

Manufacturing Processes

Prepared by Prof.S.C.Kulkarni & Prof. Jay Gavade

Page 86

FABTECH College of Engineering and Research, Sangola 4. Drawing Process a) Wire Drawing b) Tube Drawing c) Cup Drawing d) Redrawing 5. Sheet Metal Forming Process 6. Forming by bending a) V-bending b) Tube bending c) Roll bending d) Roller Straightening e) Pipe bending 7. Forming by shearing a) Shear forming b) Embossing c) Twist Forming 8. Forming by Spinning - a) Manual Spinning 2) Machine Spinning 9. Forming by Flow turning a) Flow forming b) Roto forming 10. Forming by Tension & High pressure 11. High energy rate forming process a) Explosive forming b) Electro hydraulic c) Magnetic pulse forming 12. Forming by Laser Beam /Plasma Arc -

UNIT 6

Advantages of Metal Forming:1. During forming the cast structure gets homogenized. The grain structure gets refined. This result in better mechanical properties. 2. Shrinkage cavities & some blow holes get welded. Forming by compressive forces reduces voids in material. 3. The component shapes are formed by plastic deformation hence there is no loss of material in the form of chips but there is wastage in the form of trimming as in the die forging & sheet metal blanking. 4. In hot forming the material has low strength & higher ductility hence large components may be formed. 5. During the forming, the grains & impurities get compressed in the direction of compressive forces & are elongated in the direction perpendicular to it. Fibres are developed & material gets directional properties & can take high load across the fibres. 6. In cold forming the strain hardening improves the mechanical properties of the formed components. 7. The directional properties which develop during cold rolling of sheet metal are usually used to get deeper draws in sheet metal forming. 8. In cold forming high surface finish & very close dimensional tolerance can be obtained.
Manufacturing Processes Prepared by Prof.S.C.Kulkarni & Prof. Jay Gavade Page 87