Overview of Metal Forming Overview of Metal Forming

F i /B lk D f ti Forming/Bulk Deformation
Forming/Bulk Deformation Processes Forming/Bulk Deformation Processes
are those processes in which
material is plastically deformed to mater al s plast cally deformed to
the desired shape and size.
Metal Forming Metal Forming
Metal forming includes a large group of
manufacturing processes in which plastic
deformation is used to change the shape of metal
work pieces work pieces
Plastic deformation: a permanent change of
shape, i.e., the stress in materials is larger than shape, i.e., the stress in materials is larger than
its yield strength
Usually a die is needed to force deformed metal Usually a die is needed to force deformed metal
into the shape of the die
Metal Forming
Metal with low yield strength and high ductility
is in favor of metal forming s n favor of metal form ng
One difference between plastic forming and
metal forming is
Plastic: solids are heated up to be polymer melt Plastic: solids are heated up to be polymer melt
Metal: solid state remains in the whole process Metal: solid state remains in the whole process
Metal Forming
Metal forming is divided into: (1) bulk and (2) sheet
g
Bulk: (1) significant deformation
(2) massive shape change
(3) surface area to volume of the work is small (3) surface area to volume of the work is small
Sheet: Surface area to volume of the work is large Sheet: Surface area to volume of the work is large
Characteristics of Forming Processes
1.Equipment expensive because of the large forces q p p g
involved.
2.Large capital expenditure because of heavy presses
and dies and dies.
3.Suited for a large number of parts only.
4 P d ti t i f t 4.Production rate is fast.
5.Advantage of near net-shape forming.
Categories of Forming Categories of Forming
Cold Working Cold Working
- Performed at room temperature or slightly
above
- Minimum or no machining usually required,
net shape or near-net shape process
Hot Working
- Performed at above re-crystallization rform at a o r crysta zat on
temperature (temperature at which new
strain-free grains are formed by annealing)
M hi i i d - Machining required
Cold Working vs. Hot
k ( ) Working (Advantages)
Cold Working Hot Working Cold Working Hot Working
Better accuracy,
closer tolerances
Shape of part can be
significantly altered closer tolerances significantly altered
Better surface
finish
Lower force and power
required
Strain hardening
increases strength &
hardness
No strengthening of part
occurs advantageous in case
when part is subsequently hardness when part is subsequently
processed by cold forming
No heating of work Metals that usually fracture in
required (less total
energy)
cold working can be hot
formed
Friction in Metal Forming
In most metal forming processes friction is
Friction in Metal Forming
In most metal forming processes, friction is
undesirable:
Metal flow is retarded
Forces and power are increased
Wears tooling faster
Metalworking lubricants are applied to tool-
k i t f i f i ti work interface in many forming operations
to reduce harmful effects of friction
Forming/Bulk Deformation Forming/Bulk Deformation
Types of Forming Types of Forming