FORMING (METAL-WORKING)

Presentation By:
Aaqib Zaman (BSME-14-006)
Saqib Ali (BSME-14-005)
Sajid Hussain (BSME-14-008)
Contents
Introduction
Types Of Forming
Forming Processes
Characteristics
Advantages
Disadvantages
 Introductio
n
Forming (metal forming) is themetalworkingprocess of fashioning metal parts and
objects through mechanical deformation, the work piece is reshaped without adding
or removing material, and its mass remains unchanged.

Metal forming is a manufacturing process in which forces are applied on raw

material such that stresses induced in the material are greater than yield stress and
less than ultimate stress.

The material experiences plastic deformation to change the shape of the

component and converted to the desired shape of the component.
Types Of Forming Process
Forming process can be broadly classified into two types as cold working and hot
working.
Cold Working:
Deforming the material at a temperature below the recrystallization
temperature of the work metal is called cold working. In cold working process,
strength and hardness increases due strain hardening, but ductility decreases.
 Hot Working:
Deforming the material at a temperature higher or equal to the
recrystallization temperature of the work metal is called hot working. In hot working,
refinement of grain size occurs, thus, improvingmechanical properties. Even a
brittle material can be hot worked.
Forming processes:

Forming processesare particular manufacturing processes which make use of

suitable stresses (like compression, tension, shear or combined stresses) to
causeplastic deformationof the materials to produce requiredshapes. During
forming processes no material is removed, i.e. they are deformed and displaced.
Some of example of forming processes are:
Forging
Extrusion
Rolling
Sheet metal working
Rotary swaging
Thread rolling
Explosive forming
Electromagnetic forming
Forming processes tend to be categorized by differences in effective stresses.
Compressive forming
Compressive forminginvolves those processes where the primary means of
plastic deformation is uni- or multiaxial compressive loading.
Rolling: where the material is passed through a pair of rollers.
Extrusion: where the material is pushed through an orifice
 Die forming: where the material isstampedby apressaround or onto a die
Forging: where the material is shaped by localized compressive forces
 Tensile forming

Tensile forminginvolves those processes where the primary means of plastic

deformation is uni- or multiaxial tensile stress.
Stretching: where a tensile load is applied along the longitudinal axis of the work
piece
Expanding: where the circumference of a hollow body is increased by tangential
loading
Recessing: where depressions and holes are formed through tensile loading
 Combined tensile and compressive forming
This category of forming processes involves those operations where the primary
means of plastic deformation involves both tensile stresses and compressive loads.
Deep drawing: Deep drawingis asheet metalforming process in which a sheet
metal blank is radially drawn into a forming die by the mechanical action of a
punch.
Spinning: Metal spinning, also known asspin formingorspinningormetal
turningmost commonly, is ametalworkingprocess by which a disc or tube of
metal is rotated at high speed and formed into anaxially symmetric part.
 Bending
This category of forming processes involves those operations where the primary
means of plastic deformation is a bending load.

Shearing
This category of forming processes involves those operations where the primary
means of plastic deformation is a shearing load.
Characteristics:

Metal forming tends to have more uniform characteristics across its sub
processes than its contemporary processes,cutting andjoining.

On the industrial scale, forming is characterized by:

i. Very high loads andstressesrequired, between 50 and2500 N/mm 2(7-
360ksi)
ii. Large, heavy, and expensive machinery in order to accommodate such high
stresses and loads
iii. Production runs with many parts, to maximize the economy of production and
compensate for the expense of the machine tools
Advantages:
The amount of wastage of metal during metal forming process is negligible.
Grain orientation is possible.
Because of grain orientation the material is converted from isotropic to
anisotropic material.
In most of engineering applications it requires anisotropic material.
Sometimes the strength and hardness of work material is increasing.
Some other metal forming process, the surface finish obtained on the
component is very good and excellent.
Disadvantages:

Higher mount of force and energy is required for metal forming process
compared to other manufacturing methods.
Except theforging operation, all other metal forming process are used for
producing uniform cross sectioned components only.
The components with cross holes cannot be produced easily using metal
forming process.
Thank You