Manufacturing Process

UNIT –IV
Metal Forming Processes

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 Introduction
• 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.
• Slab (500-1800 mm wide and 50-300 mm thick)
• Billets (40 to 150 sq mm)
• Blooms (150 to 400 sq mm)
• Sometimes continuous casting methods are also used to cast
the liquid metal into slabs, billets or blooms.
• These shapes are further processed through hot rolling,
forging or extrusion, to produce materials in standard form
such as plates, sheets, rods, tubes and structural sections.

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 Sequence of operations for obtaining
different shapes

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 Metal forming 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 the yield strength of the metal
– The metal takes a shape determined by the
geometry of the die

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 Basic Types of
Metal Forming Processes
1. Bulk deformation
– Rolling processes
– Forging processes
– Extrusion processes
– Wire and bar
drawing
2. Sheet
metalworking
– Bending
operations
– Deep or cup
drawing
– Shearing
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 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

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 Hot and cold working processes

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 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

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 Advantages of Cold Forming

• 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
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 Disadvantages of Cold Forming
• Higher forces and power required
for deformation
• Surfaces of starting work must be free of
scale and dirt
• Ductility and strain hardening limit the
amount of forming that can be done
– In some cases, metal must be annealed before further
deformation can be accomplished
– In other cases, metal is simply not ductile enough to be
cold worked

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 Hot Working
• Deformation at temperatures above the re crystallization
temperature.
• The process of formation of new grains is called
recrystallisation process and corresponding temperature
is called recrystallisation temperature
– Recrystallization temperature = about one-half of
melting point on absolute scale
• 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

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 Advantages of Hot Working
• Work piece shape can be significantly
altered
• Lower forces and power required
• 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
– Advantageous in cases when part is to be subsequently
processed by cold forming
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 Disadvantages of Hot Working
• Lower dimensional accuracy
• Higher total energy required, which is the
sum of
– The thermal energy needed to heat the workpiece
– Energy to deform the metal
• Work surface oxidation (scale)
– Thus, poorer surface finish
• Shorter tool life
– Dies and rolls in bulk deformation
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 Poll Question
At what temperature is hot working performed?
A) Below recrystallization temperature
B) Above recrystallization temperature
C) At room temperature
D) At absolute zero

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 Hot working operations
• Forging
• Rolling
• Welding
• Extrusion
• Spinning
• Hot piercing and rolling

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 Cold working operations
• Cold rolling
• Extrusion
• Pressing
• Deep drawing
• Squeezing
• Bending
• Shearing

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 Bulk Deformation Processes
Rolling: Compressive deformation process in which the thickness of a
plate is reduced by squeezing it through two rotating cylindrical
rolls.

Forging: The work piece is compressed between two opposing dies so

that the die shapes are imparted to the work.

Extrusion: The work material is forced to flow through a die opening

taking its shape

Drawing: The diameter of a wire or bar is reduced by pulling it through

a die opening (bar drawing) or a series of die openings (wire
drawing)
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 Basic bulk deformation processes: (a) rolling (b) Forging

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 Basic bulk deformation processes: (c) extrusion (d)
Drawing
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 Poll Question
In which process is the workpiece compressed between two
opposing dies?
A) Rolling
B) Forging
C) Extrusion
D) Drawing

The diameter of a wire is reduced by pulling it through a

series of dies in which process?
A)Rolling
B)Forging
C)Extrusion
D)Drawing
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 Basic sheet metalworking operations: (a) bending (b)
Drawing
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https://youtu.be/n3K3YlP1bvI
 Basic sheet metalworking operations: (c) shearing

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 Comparison of Hot and Cold Working
Sr. Hot Working Cold Working
No
1 Working above Working below recrystallization
recrystallization temperature temperature
2 Formation of new crystals (Grains) No crystal formation (Grains)
3 Surface finish not good Surface finish is good
4 No stress formation Internal Stress developed
5 Improved Mechanical Property due Leads to distortion of
to grain formation metal grains
6 Closed dimensional tolerances Superior dimensions can
cannot be maintained be obtained
7 Improves some mechanical During process, strength
properties like impact strength and elongation decreases
and elongation
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 Friction in Metal Forming
• In most metal forming processes, friction is
undesirable:
– Metal flow is retarded
– Forces and power are increased
– Wears tooling faster
• Friction and tool wear are more severe in
hot working
• if the co efficient of friction is very high, that
condition is called as sticking or sticking friction

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 Lubrication in Metal Forming
• Metal working lubricants are applied to tool-work
interface in many forming operations to reduce
harmful effects of friction
• Lubricant for cold working processes are mineral oil,
fats and fatty oils, soaps
• Lubricants for hot working processes are
mineral oils, graphite, moltan glass etc

• Benefits:
– Reduced sticking, forces, power, tool wear
– Better surface finish
– Removes heat from the tooling

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 Hot rolling
• Deformation process in which work thickness is
reduced by compressive forces exerted by two
opposing rolls

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• The cross section of the work piece is reduced by the
process. The material gets squeezed between a pair
of rolls, as a result of which the thickness gets
reduced and the length gets increased.
• Mostly, rolling is done at high temperature, called hot
rolling because of requirement of large deformations.
Hot rolling results in residual stress-free product.
• Bloom is has a square cross section, with area more
than 230 cm2. A slab, also from ingot, has rectangular
cross-section, with area of at least 100 cm2 and width
at least three times the thickness. A billet is rolled out
of bloom, has at least 40 mm X 40 mm cross-section.
• Blooms are used for rolling structural products such
as I-sections, channels, rails etc. Billets are rolled into
bars, rods. Bars and rods are raw materials for
extrusion, drawing, forging, machining etc. Slabs are
meant for rolling sheets, strips, plates etc.
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 Types of rolling mills
• Rolling Mills
• Equipment is massive and expensive
• Rolling mill configurations:
 Two-high – two opposing rolls
 Three-high – work passes through rolls in both
directions
 Four-high – backing rolls support smaller
work rolls
 Cluster mill – multiple backing rolls on
smaller rolls
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 ARRANGEMENTS OF
ROLLERS USED IN
ROLLING MILLS
TWO HIGH MILL
The stock is
returned to the
entrance for
further reduction.

THREE HIGH MILL

Consist of upper and
lower driven rolls and
a middle roll, which
rotates by friction.
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 FOUR HIGH MILL
Small-diameter rolls
(less strength &
rigidity) are
supported by
larger-diameter
backup rolls

CLUSTER ROLLING
MILLS

Each of the work

rolls is supported
by two backing
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rolls.
 REFERENCE VIDEO
https://youtu.be/jCzJpGYVlGY

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Sr. Open Die forging Closed die forging
No
1 In this method, the work piece is Work piece is compressed
compressed between two flat dies between two impressed dies
2 Cost of dies are low Higher cost
3 The process is simple process is complex

4 No stress formation Residual stress formation takes

place
5 During process, poor utilization Better utilization
of metals
6 After the process, machining Machining of component is
of component is required not required
7 Dimensional accuracy is not good Dimensional accuracy is good

8 Suitable only for production of Simple and complex component

simple component PROF. V.V.SHINDE P'S KBT COE
28/07/
2
NDMV
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 REFERENCE VIDEO
https://youtu.be/YobXFODkp50

https://youtu.be/5L8mSLyN7yA

https://youtu.be/rMHgUE4xUyI

https://youtu.be/AXiDluxlXT0

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 Extrusion
• A plastic deformation process in which metal is forced
under pressure to flow through a single, or series of dies
until the desired shape is produced.
• Process is similar to squeezing toothpaste out of a toothpaste
tube
• In general, extrusion is used to produce long parts of uniform
cross sections
• Typical products made by extrusion are railings for sliding doors,
tubing having carious cross-sections, structural and architectural
shapes, door and windows frames.

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 Types
(1)Direct Extrusion (Forward Extrusion)
(2)Indirect Extrusion (Backward Extrusion)
(3)Cold Extrusion
(4)Hot Extrusion
• Direct Extrusion
• Billet is placed in a chamber and forced through a die
opening by a hydraulically-driven ram or pressing stem.
• Dies are machined to the desired cross-section

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• Indirect Extrusion
• Metal is forced to flow through the die in an opposite
direction to the ram’s motion.
• Lower extrusion force as the work billet metal is not
moving relative to the container wall.
• Limitations
• Lower rigidity of hollow ram
• Difficulty in supporting extruded product as it exits
die

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 REFERENCE VIDEO
https://youtu.be/P8BWQBP4Vhk
https://youtu.be/HuL7A0QmPbQ

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 Drawing
• Commonly used to make wires from round bars
• Large quantities of wires, rods, tubes and other sections
are produced by drawing process which is basically a cold
working process.
• In this process the material is pulled through a die in order
to reduce it to the desired shape and size.
• In a typical wire drawing operation, once end of the wire
is reduced and passed through the opening of the die,
gripped and pulled to reduce its diameter.

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• 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. Drawn rods are used for
shafts, spindles, and small pistons and as the raw material
for fasteners such as rivets, bolts, screws.
• Drawing also improves strength and hardness when these
properties are to be developed by cold work and not by
subsequent heat treatment.

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• Wire drawing machines consisting of multiple draw
dies (typically 4 to 12) separated by accumulating
drums
 Each drum (capstan) provides proper force to draw
wire stock through upstream die
 Each die provides a small reduction, so desired
total reduction is achieved by the series

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• Die Materials
 Commonly used materials are Tool Steels and
Carbides
 Diamond dies are used for fine wire.
 For improved wear resistance, steel dies may be
chromium plated, and carbide dies may be coated
with titanium nitride
 For Hot drawing, cast-steel dies are used

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 Tube drawing
• Tube drawing is also similar to wire drawing, except that a
mandrel of appropriate diameter is required to form the
internal hole.
• The process reduces the diameter and thickness of the
tube.
• Tube drawing is very similar to bar drawing, except the
beginning stock is a tube. It is used to decrease the diameter,
improve surface finish and improve dimensional accuracy.
• A mandrel may or may not be used depending on the
specific process used.

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 Tube Drawing

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