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Lec 9 Forming

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18 views32 pages

Lec 9 Forming

Uploaded by

Lojy Badr
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Production Engineering

Dr. Ehab Nossier

Metal Forming
Metal Forming

Metal forming processes can be classified


into two basic categories:

1. bulk deformation processes


2. sheet metalworking
Bulk Deformation Process
Bulk deformation processes are generally
characterized by significant deformations and
massive shape changes and the surface area-to-
volume of the work is relatively small.

Basic bulk deformation processes shown in Figure:


(a) rolling, (b) forging, (c) extrusion, and (d)wire drawing.
Relative motion in the operations is indicated by v;
Forces are indicated by F.
Sheet Metal Work
Sheet metal working processes are forming and
cutting operations performed on metal sheets,
strips. The surface area-to-volume ratio of the
starting metal is high.

Basic sheet metal working operations shown in


Figure:
(a) bending, (b)Deep drawing, and
(c) shearing: (1) as punch first contacts sheet, and
(2) after cutting.

Force and relative motion in these operations are


indicated by F and v.
Temperature in Metal Forming

Cold Working: (also known as cold forming) is metal forming performed at room temperature or slightly above.

Advantages of cold forming:


(1) Better accuracy, closer tolerances
(2) better surface finish
(3) no heating of the work is required, which saves costs
(4) higher production rates.

Disadvantages or limitations:
(1) higher forces and power are required
(2) surfaces of the starting workpiece must be free of scale and dirt
(3) Ductility and strain hardening of the work metal limit the amount of forming that can be done to the part.
Temperature in Metal Forming
Hot working: (also called hot forming) involves deformation at temperatures above the recrystallization temperature.
The recrystallization temperature for a given metal is about half of its melting point on the absolute scale (0.5 Tm). In
practice, hot working is usually carried out at temperatures somewhat above The work metal continues to soften as
temperature is increased beyond 0.5Tm, thus enhancing the advantage of hot working above this level.

Advantages of cold forming:


(1) The shape of the work part can be significantly altered,
(2) Lower forces and power are required to deform the metal
(3) Metals that usually fracture in cold working can be hot formed

Disadvantages or limitations:
(1) Lower dimensional accuracy
(2) Higher total energy required (due to the thermal energy to heat the workpiece)
(3) Work surface oxidation ,poorer surface finish
Bulk Deformation Process
1. Rolling
Deformation process in which work thickness is reduced by compressive forces exerted by two opposing rolls

Rotating rolls perform two main functions:


▪ Pull the work into the gap between them by friction between workpiece and rolls
▪ Simultaneously squeeze the work to reduce its cross section
Types of Rolling:
▪ Based on workpiece geometry :
▪ Flat rolling - used to reduce thickness of a rectangular
cross section
▪ Shape rolling - square cross section is formed into a
shape such as an I-beam

▪ Based on work temperature :


▪ Hot Rolling – most common due to the large amount of
deformation required
▪ Cold rolling – produces finished sheet and plate stock
Diagram of Flat Rolling

Draft = amount of thickness reduction

d = 𝑡𝑜 − 𝑡𝑓

where d = draft
𝑡𝑜 = starting original thickness;
𝑡𝑓 = final thickness

Reduction = draft expressed as a fraction of starting thickness

𝑑
r=
𝑡𝑜
Shape Rolling:
Work is deformed into a contoured cross
section rather than flat (rectangular)

Accomplished by passing work through


rolls that have the reverse of desired
shape

Products include:
• Construction shapes such as I-beams,
L-beams, and U-channels
• Rails for railroad tracks
• Round and square bars and rods
Rolling
Bulk Deformation Process
2. Forging
Forging is a deformation process in which the work is compressed
between two dies, using either impact or gradual pressure to form the
part. It is the oldest of the metal forming operations.

Today, forging is an important industrial process used to make engine


crankshafts and connecting rods, and jet engine turbine parts.

Types of forging operation:


(A) open-die forging: the work is compressed between two flat (or
almost flat) dies, thus allowing the metal to flow without constraint in a
lateral direction relative to the die surfaces.

(B) Closed-die forging: the die surfaces contain a shape or impression


that is imparted to the work during compression, thus constraining
metal flow to a significant degree. In this type of operation, a portion of
the work metal flows beyond the die impression to form flash. Flash is
excess metal that must be trimmed off later
Forging
Open-Die Forging
Closed-Die Forging
Forging
Bulk Deformation Process
3. Extrusion
Compression forming process in which work metal is forced to flow through a die opening to produce a
desired cross-sectional shape

▪ Process is similar to squeezing toothpaste out of a toothpaste tube


▪ In general, extrusion is used to produce long parts of uniform cross sections

Types of Extrusion:
▪ Direct extrusion
▪ Indirect extrusion
Direct extrusion: (also called forward extrusion) A metal billet is loaded into a container, and a ram compresses the
material, forcing it to flow through one or more openings in a die at the opposite end of the container.

As the ram approaches the die, a small portion of the billet remains that cannot be forced through the die opening.
This extra portion, called the butt, is separated from the product by cutting it just beyond the exit of the die.
Indirect extrusion: also called backward extrusion and reverse extrusion. the die is mounted to the ram rather than at
the opposite end of the container.

As the ram penetrates into the work, the metal is forced to flow through the clearance in a direction opposite to the
motion of the ram.

Since the billet is not forced to move relative to the container, there is no friction at the container walls, and the ram
force is therefore lower than in direct extrusion.

There are practical limitations on the length of the extruded part that can be made by this method. Support of the
ram becomes a problem as work length increases.

Indirect extrusion to produce (a) a solid cross section and (b) a hollow cross section.
Extrusion
Extrusion Ratio

Also called the reduction ratio, it is defined as

𝐴𝑜
𝑟𝑋 =
𝐴𝑓

where rx = extrusion ratio


Ao = cross-sectional area of the starting billet
Af = final cross-sectional area of the extruded section

▪ Applies to both direct and indirect extrusion


Other Extrusion Processes

Impact Extrusion: is performed at higher speeds and shorter strokes than conventional extrusion. It is used to make
individual components.

Impacting can be carried out as forward extrusion, backward extrusion, or combinations of these.
Impact Extrusion
Wire Drawing
Sheet Metal Work

Sheets produced by flat rolling are used in secondary sheet metal forming processes:
1. Cutting
▪ Shearing to separate large sheets
▪ Blanking to cut part perimeters out of sheet metal
▪ Punching to make holes in sheet metal
2. Drawing
▪ Forming of sheet into shapes

Advantages of Sheet Metal Parts


▪ Good dimensional accuracy
▪ Good surface finish
▪ Relatively low cost
▪ Economical mass production for large quantities
Sheet Metal Work
1. Cutting
Shearing is a sheet-metal cutting operation along a straight line
between two cutting edges. Shearing is typically used to cut
large sheets into smaller sections for further operations.

Blanking involves cutting of the sheet metal along a closed


outline in a single step to separate the piece from the
surrounding stock. The part that is cut out is the desired
product in the operation and is called the blank.

Punching is similar to blanking except that it produces a hole,


and the separated piece is scrap, called the slug. The remaining
stock is the desired part. (a) Blanking and (b) punching.
Shearing
Blanking
Bending
Sheet Metal Work
2. Deep Drawing
Sheet metal forming to make cup-shaped, box-shaped, or
other complex-curved, hollow-shaped parts

▪ Sheet metal blank is positioned over die cavity and


then punch pushes metal into opening
▪ Products: beverage cans, ammunition shells,
automobile body panels.
Deep Drawing
Spinning

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