Fundamentals of Metal

Forming
Chapter 18

Manufacturing Processes, MET 1311

Dr Simin Nasseri
Southern Polytechnic State University
(© Fundamentals of Modern Manufacturing; Materials, Processes and Systems,
by M. P. Groover)

1
FUNDAMENTALS OF METAL FORMING

1. Overview of Metal Forming

2. Material Behavior in Metal Forming
3. Temperature in Metal Forming

Manufacturing Processes, Prof Simin Nasseri 2

Metal Forming
Large group of manufacturing processes in which plastic
deformation is used to change the shape of metal
workpieces

 The tool, usually called a die,

applies stresses that exceed
the yield strength of the metal

 The metal takes a shape

determined by the geometry of
the die

Manufacturing Processes, Prof Simin Nasseri 3

Stresses in Metal Forming
 Stresses to plastically deform the metal are usually
compressive
 Examples: rolling, forging, extrusion

 However, some forming processes

 Stretch the metal (tensile stresses)
 Others bend the metal (tensile and compressive)
 Still others apply shear stresses

Manufacturing Processes, Prof Simin Nasseri 4

Material Properties in Metal
Forming
 Desirable material properties:
 Low yield strength
 High ductility

These properties are affected by temperature:

Ductility increases and yield strength decreases
when work temperature is raised

T Ductility Yield Strength

Manufacturing Processes, Prof Simin Nasseri 5

 Basic Types of Deformation
Processes
1. Bulk deformation
 Rolling
 Forging
 Extrusion
 Wire and bar drawing
2. Sheet metalworking
 Bending
 Deep drawing
 Cutting
 Miscellaneous processes

Manufacturing Processes, Prof Simin Nasseri 6

Bulk Deformation

7
Bulk Deformation Processes
 Characterized by significant deformations and
massive shape changes

 "Bulk" refers to workparts with relatively low

surface area‑to‑volume ratios
 Starting work shapes include cylindrical billets and
rectangular bars

Manufacturing Processes, Prof Simin Nasseri 8

 Rolling

The slab is heated in a furnace and

rolled between powered rollers until
the plate is made with desirable
thickness.

Figure 18.2 Basic bulk

deformation processes: (a) rolling

Manufacturing Processes, Prof Simin Nasseri 9

 Forging

Forging is the process of forming the metal by impacting and/or

squeezing a preheated part between two halves of a die. A
succession of dies may be needed to achieve the final shape.

Figure 18.2 Basic bulk deformation

processes: (b) forging
Manufacturing Processes, Prof Simin Nasseri 10
 Extrusion
Billets are preheated and forced by a ram through one or more dies
to achieve the desired cross-section. The product is long in relation
to its cross-sectional dimensions and has a cross section other than
that of rod and bar and pipe and tube.

Aluminum
part

Figure 18.2 Basic

bulk deformation
processes: (c)
extrusion
Manufacturing Processes, Prof Simin Nasseri 11
Wire and Bar Drawing
Drawing is an operation in which
the cross-section of solid rod, wire
or tubing is reduced or changed in
shape by pulling it through a die.

Figure 18.2 Basic bulk

deformation processes:
(d) drawing

Manufacturing Processes, Prof Simin Nasseri 12

Sheet Metal
Working

13
Sheet Metalworking
 Forming and related operations performed on
metal sheets, strips, and coils
 High surface area‑to‑volume ratio of starting
metal, which distinguishes these from bulk
deformation
 Often called pressworking because presses
perform these operations
 Parts are called stampings
 Usual tooling: punch and die

Manufacturing Processes, Prof Simin Nasseri 14

 Sheet Metal Bending

Straining of a metal sheet or

plate to take an angle.

Figure 18.3 Basic sheet

metalworking operations: (a)
bending

Manufacturing Processes, Prof Simin Nasseri 15

 Deep Drawing
Forming of a flat metal sheet into
a hollow or concave shape, by
stretching the metal.

Figure 18.3 Basic sheet metalworking operations: (b) drawing

Manufacturing Processes, Prof Simin Nasseri 16

 Shearing of Sheet Metal

Shearing operation which cuts

the work by using a punch and
die.

Figure 18.3 Basic sheet metalworking operations: (c) shearing

Manufacturing Processes, Prof Simin Nasseri 17
Test yourself!
 Name the metal forming process used for each object (bulk deformation or sheet metalworking).

sheet metalworking

Manufacturing Processes, Prof Simin Nasseri 18

Test yourself!
 Name the metal forming
process used for each object.

sheet metalworking

sheet metalworking
Manufacturing Processes, Prof Simin Nasseri 19
Test yourself!
 Name the metal forming process used for each object.

Bulk deformation

Manufacturing Processes, Prof Simin Nasseri 20

Test yourself!
 Name the metal forming process used for each object.

sheet metalworking

Manufacturing Processes, Prof Simin Nasseri 21

Test yourself!
 Name the metal forming
process used for each object.

Forging (Bulk
deformation)

Manufacturing Processes, Prof Simin Nasseri 22

Test yourself!

Extrusion (bulk deformation)

Manufacturing Processes, Prof Simin Nasseri 23

Test yourself!

Gutter

Bending
Deep drawing
sheet metalworking

Manufacturing Processes, Prof Simin Nasseri 24

Temperature in Metal
Forming
25
Temperature in Metal Forming
 Any deformation operation can be accomplished with lower
forces and power at elevated temperature
Three temperature ranges in metal forming:

 Cold working

 Warm working

 Hot working

Manufacturing Processes, Prof Simin Nasseri 26

Temperature in Metal Forming
Cold working refers to plastic deformation
that occurs usually, but not necessarily, at
room temperature.

Warm working: as the name implies, is

carried out at intermediate temperatures. It
is a compromise between cold and hot
working.

Hot working refers to plastic deformation

carried out above the recrystallization
temperature.

Manufacturing Processes, Prof Simin Nasseri 27

Temperature in Metal Forming

Increasing temperature

Melting temperature

Room temperature 0.3 Tm 0.5 Tm Tm Above Tm

Warm Working

Recrystallization
Cold working

Hot working

Casting
Manufacturing Processes, Prof Simin Nasseri 28
Cold Working
 Performed at room temperature or
slightly above
 Cold Forming is the primary
manufacturing operation of the
fastener industry.

 Many cold forming processes are

important mass production operations

 These operations are near net shape

or net shape processes (Minimum or
no machining usually required)

Manufacturing Processes, Prof Simin Nasseri 29

 Advantages of Cold Forming
 Better accuracy, closer
tolerances

 Better surface finish

 No heating of work required

Cold forming can make tiny, complex

precision parts in one machining
step. Tolerances of 0.0005 in. are
possible.

Manufacturing Processes, Prof Simin Nasseri 30

Disadvantages of Cold Forming

 Higher forces and power required in the

deformation operation
 Ductility and strain hardening limit the
amount of forming that can be done
 In some cases, metal is simply not ductile enough
to be cold worked

Manufacturing Processes, Prof Simin Nasseri 31

Warm Working
 Performed at temperatures above room temperature
but below recrystallization temperature

 Dividing line between cold working and warm working often

expressed in terms of melting point:
 0.3Tm,
where Tm = melting point (absolute temperature) for metal

Manufacturing Processes, Prof Simin Nasseri 32

 Advantages of Warm Working
 Lower forces and power than in cold
working

 More complex work geometries possible

Manufacturing Processes, Prof Simin Nasseri 33

Hot Working
 Deformation at temperatures above the
recrystallization temperature
 Capability for substantial plastic deformation of the metal ‑ far
more than possible with cold working or warm working

 Recrystallization temperature = about one‑half of

melting point
 In practice, hot working usually performed
somewhat above 0.5Tm (Metal continues to soften as
temperature increases above 0.5Tm, enhancing advantage of hot
working above this level)

Manufacturing Processes, Prof Simin Nasseri 34

Advantages of Hot Working
 Workpart shape can
be significantly
altered

 Lower forces and

power required

 Metals that usually

fracture in cold
working can be hot
formed

Manufacturing Processes, Prof Simin Nasseri 35

Disadvantages of Hot Working
 Lower dimensional accuracy

 Higher total energy required (due to the thermal

energy to heat the workpiece)

 Shorter tool life

Manufacturing Processes, Prof Simin Nasseri 36