14ME230 Metal Forming Processes

What is Manufacturing?
The word manufacture is derived from two Latin
words manus (hand) and factus (make); the
combination means “made by hand”
It encompasses (1) Design of the product (2)
selection of raw materials (3) Sequence of
processes
Most modern manufacturing operations are
accomplished by mechanized and automated
equipment that is supervised by human workers
 Basic Manufacturing Processes
– Casting (Melting and Pouring in to cavity of desired
shape and size)
– Metal Forming and shaping (Plastic Deformation
Process- Rolling, Forging, Extrusion, Drawing, Sheet
Forming)
– Machining (Removing the excess materials by relative
movement between cutting tool and work piece
material- Turning, Boring, Milling, Planing, Broaching)
– Joining (Assembling different parts or components-
welding, brazing , soldering )
– Finishing (Honing, Lapping, Polishing, burnishing,
deburring, coating and plating)
 Manufacturing Processes: Casting

Figure a Schematic illustration of various casting processes

 Manufacturing Processes: Forming and Shaping

Figure b Schematic illustration of various bulk deformation processes

 Manufacturing Processes: Forming and Shaping

Figure c Schematic illustration of various sheet metal forming processes

 Manufacturing Processes: Joining

Figure d Schematic illustration of various joining processes

Manufacturing Processes: Machining

Figure e Schematic illustrations of various

machining and finishing processes.
Elastic and Plastic Deformation
 Metal Forming or Bulk Deformation
Processes
 Large group of manufacturing processes in which plastic
deformation is used to change the shape of metal work
pieces
 The tool, usually called a die, applies stresses that exceed
yield strength of metal .
 The metal takes a shape determined by the geometry of
the die
 Practically all metals, which are not used in cast form are
reduced to some standard shapes for subsequent
processing.
 Manufacturing companies producing metals supply metals
in form of ingots which are obtained by casting liquid metal
into a square cross section.
 Fundamentals of Metal Forming
Processes
Plastic Deformation Process
Plastic deformation in a metal can be achieved by the
application of large amount of mechanical force only or by
heating the metal and then applying a small force.
Plastic deformation processes exploit a remarkable
property of metals, which is their ability to flow plastically
in the solid state without deterioration of their properties.
With the application of suitable pressures, the material is
moved to obtain the desired shape with almost no
wastage.
The required pressures are generally high and the tools
and equipment needed are quite expensive.
Large production quantities are often necessary to justify
the process.
Overview of Metal Forming
• Bulk Deformation Processes:
- Compressive deformation force
- Significant deformations
- Massive shape changes
- Starting work shapes include
Surface Area /
Volume
billets and rectangular bars
is small

• Sheet metal working:

- Also called “Pressworking”
- Cold working processes
- Use set of punch and die
- Performed on metal sheets,
Surface Area /
Volume strips and coils
is large
 Metal Forming

Bulk Deformation Sheet Metal Working

Forging – compression process Bending – straining of a metal sheet to

performing between a set of opposing form a angle bend
dies.
Deep Drawing – forming a sheet into a
Rolling – compression process to hollow or concave shape
reduce the thickness of a slab by pair
Shearing – a cutting process by slitting
of rolls.
Extrusion – compression process
squeezing metal flow a die opening
Drawing - pulling a wire, rod or bar
through a die opening
 Rolling Forging Deep Drawing
Bending

Drawing Shearing
Extrusion

Bulk Deformation Processes Sheet Metal Working

 Recrystallization Temperature
When the action of heat and force, when the atoms reaches
the higher energy level, new crystal start forming and it is
termed as recrystallization.
Recrystallization destroys the old grain structures deform by
the mechanical working and entirely new crystals which are
strain free are formed.
The approximate minimum temperature at which complete
recrystallization of a cold worked metal occurs with in a specified
time.
Varies between 1/3 to ½ of Melting point of the metal
Recrystallization
Temperature

Schematic
illustration of the
effects of
recovery,
recrystallization,
and grain growth
on mechanical
properties and on
the shape and size
of grains. Note
the formation of
small new grains
during
recrystallization.
Hot Working and Cold Working
Cold Working:
 Performed at room temperature or slightly above
 Many cold forming processes are important mass production operations
 Minimum or no machining usually required
 These operations are near net shape or net shape processes
Advantages of Cold Forming vs. Hot Working:
 Better accuracy, closer tolerances
 Better surface finish
 Strain hardening increases strength and hardness
 Grain flow during deformation can cause desirable directional properties in
product
 No heating of work required (less total energy)
Disadvantages of Cold Forming:
 Equipment of higher forces and power required
 Surfaces of starting work piece must be free of scale and dirt
 Ductility and strain hardening limit the amount of forming that can be done
 Hot Working and Cold Working
Hot Working:
o Deformation at temperatures above recrystallization temperature.
o In practice, hot working usually performed somewhat above 0.5Tm.
o Metal continues to soften as temperature increases above 0.5Tm,
enhancing advantage of hot working above this level.
Advantages of Hot Working vs. Cold Working
 Work part shape can be significantly altered
 Lower forces and power required (equipment)
 Metals that usually fracture in cold working can be hot formed
 Strength properties of product are generally isotropic
 No strengthening of part occurs from work hardening
Disadvantages of Hot Working:
 Lower dimensional accuracy
 Higher total energy required
 Warm Working
Warm Working:
 Performed at temperatures above room temperature but below
recrystallization temperature
Advantages of Warm Working:
 Lower forces and power than in cold working
 More intricate work geometries possible
 Need for annealing may be reduced or eliminated
 Warm working: T/Tm from 0.3 to 0.5