BULK FORMING PROCESSES

Anoche - Biscocho - Capapas - Laza

ME 131 WFR
Wire, Rod, and Tube
Drawing
Wire, Rod, and Tube Drawing

- Operations that reduce cross section of a material by

pulling it through a die
- Essentially similar to extrusion, but applied force is
tensile (product is pulled rather than pushing on the
workpiece)
Rod Drawing

- Also called bar drawing

- End of a rod is reduced or pointed, so it is passed through
a die of smaller cross section
- Protruding material is then placed in grips and pulled,
drawing the remained of the rod through the die
- Rods increase in strength due to strain hardening, reduce
in section, and elongate
- Area reduction is usually limited to 20-50%
- Draw benches are generally employed
Tube Drawing

- Used to produce high quality tubes that are

characteristic of cold forming
- Internal mandrels are used to form the inside diameter of
the tubes, and are inserted through the incoming stock
and held in place during operation
Tube Sinking

- Specific type of tube drawing, sacrificing precision

control of inner diameter for process simplicity, and
ability to draw long lengths of product
- Done without a mandrel, uses a floating plug insead
- Floating plug is designed only for a specific material,
reduction, and friction
Wire Drawing

- Essentially same process as bar drawing except it

involves smaller-diameter material
- Multiple draws are usually required to affect any
significant change in size
- Material usually requires annealing at final phases, and
controlling the placement of the last anneal for ductility
and conductivity
Cold Forming
Cold Forming

● Family of processes in which slugs of material are

squeezed into or extruded from shape died cavities to
produce finished parts of precise shape and size
● Chipless manufacturing process
● Weaker, nonferrous metals
● Shapes are usually axisymmetric
Basic Steps of Cold Forming

1. Forward Extrusion

-reducing diameter

2. Backward Extrusion

-making holes

3. Upset

-forming heads on fasteners

Forward Extrusion
Backward Extrusion
Upset
Cold Forming Process for Nails and Bolts
Advantages

● Production rates are high

● Dimensional tolerances and surface finish are excellent
● No draft angles, parting lines or flash to trim off
● Almost no material waste
● Smaller and thinner parts can be made
● Improvement in mechanical properties
Disadvantage

● Cost of required tooling, coupled with production speed

requires large volume production
Cold Heading
Cold Heading

● Form of upset forging

● Used for making enlarged sections on the ends of rods
and wires, such as heads of bolts, nails, rivets and other
fasteners
● Generally produces symmetrical parts
Process 1 / Variation 1

1. A rod is sheared to a preset length and is transferred to a

holder-ejector assembly
2. Heading punches strike blows on exposed end to perform
the upsetting
3. Ejector stop advances and expels the product
Process 2 / Variation 2

1. Continuous rod is fed forward to produce a preset

extension, clamped and the head is formed
2. Rod is advanced to second preset length and is then
sheared
3. The cycle repeats
Cold Heading Process of Screws
Production Speeds

● For blanks less than 6 mm or 0.25 in. in diameter, speeds

of 400 to 600 pieces per minute are typical
● For larger diameters, the speeds are 40 to 100 pieces per
minute
Formability

● Alloys of aluminum and copper have excellent formability

● Mild steel and stainless steel are rated fair to good
● Alloy steels are difficult due to higher strength and lower
ductility
Impact Extrusion
Impact Extrusion

● Variety of extrusion processes

● In these processes, a metal slug of predetermined size is
positioned in a die cavity, where it is struck a single blow
by a rapidly moving punch.
● The metal may flow forward through the die, backward
around the punch, or in a combination way.
● These variations are used with an open or closed dies.
 Backward extrusion
shapes hollow parts
with a solid bottom.
The punch controls
the inside shape while
the die shapes the
exterior.
In forward extrusion,
diameter decreases as
length increases.
 The wall thickness is
determined by the
clearance between
the punch and the die.
The bottom thickness
is set by the stop
position of the punch.
Backward Forward Combination
Piercing
Piercing Process

● Thick-walled seamless tubing can be made by rotary

piercing.
● A heated billet is fed longitudinally into the gap between
two large, convex-tapered rolls.
● These rolls are rotated in the same direction, but the axes
of the rolls are offset from the axis of the billet by about
6°, one to the right and the other to the left. The
clearance between the rolls is pre-set at a value less than
the diameter of the incoming billet.
Piercing Process

● As the billet is caught by the rolls, it is simultaneously

rotated and driven forward. The reduced clearance
between the rolls forces the billet to deform into a
rotating ellipse.
● Rotation of the elliptical section causes the metal to
shear about the major axis. A crack tends to form down
the center axis of the billet, and the cracked material is
then forced over a pointed mandrel that enlarges and
shapes the opening to create a seamless tube.
Piercing Process
● The result is a short length of thick-walled seamless
tubing, which can then be passed through sizing rolls to
reduce the diameter and/or wall thickness. Seamless
tubes can also be expanded in diameter by passing them
over an enlarging mandrel. As the diameter and
circumference increase, the walls correspondingly thin.
OTHER SQUEEZING
PROCESSES
 ROLL EXTRUSION
- Used for producing thin walled cylinders from thick
walled cylinders
- Expands diameter by squeezing the rotating material
using rollers
- As wall thickness is reduced, cylinder elongates
- Two configurations:
a. Internal rollers
- Expands internal diameter
- Squeeze against external confining ring
b. External rollers
- Expands external diameter
- Squeeze against internal mandrel
 SIZING
- Squeezing all or selected regions of forging, ductile casting, or powder metallurgy
to achieve prescribed thickness or enhance dimensional precision
- Enables the use of less costly production methods
- Usually performed on mechanically driven presses
 RIVETING
- Expanded head is formed at the end of the fastener to join
sheet or plates of material

APPLICATION

a. TWO SIDE ACCESS

- Shaped punch may be driven by: press or contained in
riveting hammer
- Orbital forming - tendency of heading punch to rotate to
shape the head in progressive manner
b. ONE SIDE ACCESS (Blind Riveting)
- Explosive rivets
- Pop rivets
 STAKING
- method of permanently joining parts together when a
segment of one part protrudes through a hole in the other
- deformation causes radial expansion, mechanically
locking two pieces
- convenient and economical
 COINING
- refers to the cold squeezing of metal while all of the
surfaces are confined within a set of dies.
- used to produce coins, medals, and other products where
fine details and exact size and where thickness varies
about a well defined average
- Coining pressure may be as high as 1400 MPA or 200,000
psi
 HUBBING
- is a cold-working process that is used to plastically form
recessed cavities in a workpiece

PROCESS:

- A male hub (or master) is made with the reverse profile of

the desired cavity
- After hardening, the hub is pressed into an annealed block
until the desired impression is produced
- The hub is withdrawn, and the displaced metal is removed
by a facing-type machining cut
- The workpiece, which now contains the desired cavity, is
then hardened by heat treatment
QUIZ
1. It is a method of permanently joining parts together when a
segment of one part protrudes through a hole in the other

A. ROLL EXTRUSION
B. RIVETING
C. SIZING
D. STAKING
E. COINING
F. HUBBING
2. It is a method of squeezing all or selected regions of forging,
ductile casting, or powder metallurgy to achieve prescribed
thickness or enhance dimensional precision

A. ROLL EXTRUSION
B. RIVETING
C. SIZING
D. STAKING
E. COINING
F. HUBBING
3. It is a method of expanding the diameter of cylinder by squeezing
the rotating material using rollers

A. ROLL EXTRUSION
B. RIVETING
C. SIZING
D. STAKING
E. COINING
F. HUBBING
4. It refers to cold squeezing of metal while all of the surfaces are
confined within a set of dies

A. ROLL EXTRUSION
B. RIVETING
C. SIZING
D. STAKING
E. COINING
F. HUBBING
5. In cold forming, this method is used to cut holes.

A. UPSET
B. COLD HEADING
C. BACKWARD EXTRUSION
D. IMPACT EXTRUSION
E. FORWARD EXTRUSION
6. What type of forging is cold heading?

A. COLD FORMING
B. IMPACT EXTRUSION
C. FORWARD EXTRUSION
D. BACKWARD EXTRUSION
E. UPSET
7-8. Give two advantages of cold forming.
9-10. Give the two variations of impact extrusion.
11. The wall thickness of the impact extruded material is determined by the ______.

A. STOP POSITION OF THE PUNCH

B. CLEARANCE BETWEEN THE PUNCH AND DIE
C. DIAMETER OF SLUG
D. PUNCH
E. DIE
12. The bottom thickness of the impact extruded material is determined
by the ______.

A. STOP POSITION OF THE PUNCH

B. CLEARANCE BETWEEN THE PUNCH AND DIE
C. DIAMETER OF SLUG
D. PUNCH
E. DIE
13. Thick-walled seamless tubing can be produced through what process?
14. Special type of Tube Drawing.

A. Rod Drawing
B. Tube Sinking
C. Tube Drawing
D. Wire Drawing
15. Usually a multi-draw process.

A. Rod Drawing
B. Tube Sinking
C. Tube Drawing
D. Wire Drawing