METAL FORMING DEFORMATION PROCESSES

Metal forming includes a group of manufacturing

processes in which plastic deformation is used to change
the shape of metal workpiece.

The tool, usually called a die in metal forming, applies

stresses that exceed the yield strength of the metal.

Stresses applied to plastically deform the metal are

usually compressive. However some forming processes
stretch the metal, while others bend the metal, and some
apply shear stress of the metal.

To be successfully formed, a metal must posses low yield

strength and high ductility.
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METAL FORMING DEFORMATION PROCESSES

Ductility is increased and yield strength is reduced when

work temperature is raised.

Since all processing is done in solid state, there is no

need to handle molten material or deal with the
complexities of solidification.

Material is simply moved or rearranged to produce the

shape, the amount of waste can be substantially reduced.

High forces are required.

Machinery and tooling cost is high.

Use for large production quantities.

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BASIC TYPES OF DEFORMATION PROCESSES

1.

2.

Bulk deformation

Rolling

Forging

Extrusion

Wire and bar drawing

Sheet metalworking

Bending

Deep drawing

Cutting

Miscellaneous processes

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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.

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BULK DEFORMATION PROCESSES

Rolling

Extrusion

Forging

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Drawing

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

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SHEET METALWORKING

(a) bending
(b) drawing

(c) 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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ROLLED PRODUCTS MADE OF STEEL

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DIAGRAM OF FLAT ROLLING

Draft = thickness reduction:

d t o tf
Conservation of Volume:

t o wo L o t f w f L f

t o wo v o t f w f v f
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ROLLING MILLS

Various configurations of rolling mills: (a) 2-high, (b) 3-high, (c) 4-high,
(d) cluster mill, (e) tandem rolling mill
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OTHER ROLLING OPERATIONS

Thread Rolling

Ring Rolling
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ROLLING

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ROLLING

Backing rolls

Strip rolling in four stand continuous mill

Use of front and back tension to

reduce friction in rolling

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