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A Glance of Metal Forming:

A simple metallic geometry is transformed into desired
shape and size through plastic deformation
Requires high force to move and deform the material
to desired shape with little or no waste
Tools or dies impart pressure on the material in order
to form into desired shapes
Divided in terms of hot metal working process and
cold working process
E.g. forging, roll forming, extrusion, drawing and sheet
metal forming(bending)

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Expensive equipment because of the large force

involved
Large capital expenditure because of heavy presses and
dies
Suited for large number of parts only
Production rate is fast
Advantage for near net-shape forming

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No or very small loss of material, little or no scrap

Increase in ductility (hot forming of cast ingots)
Increase in strength and hardness
High production rate, generate final shape in short time
Better mechanical and metallurgical
(strength, toughness, grain size)

properties

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Definition:
Hot working is performed above the recrystallization
temperature of the material and cold working is
below the recrystallization temperature of the material.
Recrytallization temperature the approximate
minimum
temperature
at
which
complete
recrystallization of a cold worked metal occurs within a
specified time.
Approximate temperature range:
HW about 0.5 to 0.75 of the melting temperature
WW 0.3 to 0.6 melt temp of the material
CW less than 0.3 of the melting temperature of
the material

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No strain hardening taking place

Higher amount of ductility

no limit on the amount of metal working
even brittle materials can be hot worked
Requires much less
necessary deformation

force

to

achieve

A favorable grain size

Giving rise to mechanical properties
Not effecting the yield strength, hardness or
ductility

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Some of the material cannot be hot worked

because of their brittleness at high
temperature
Surface finish rather poor due to scaling at
high temperature
Dimensional accuracy is difficult to achieve
because of thermal expansion
Troublesome in handling and maintaining hot
metal

Poor tolerance due to shrinkage

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Increase the strength and hardness due to strain hardening

Good surface finish due to no oxide formed

Dimensional accuracy can be achieved

Far easier to handle since no heating is required

Improved strength, fatigue, and wear properties

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Properties
Ultimate tensile strength, MPa
Yield strength, MPa
Brinell Hardness Number

Hot Rolled

Cold Rolled

427

558

220.5

345

94

174

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Limited by the capability of the presses and hammers used

Maximum amount of deformation is limited due to strain
hardened
Some brittle material can not be hard worked
Higher forces are required and therefore heavy requirement
is needed
Less ductility available

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Term applied to metal forming process of shaping and reducing metal

thickness by pressing it between rolls
Defined as the process of reducing the thickness or cross section of
a long workpiece by compressive forces applied through a set of
rotating rolls
Flat rolling thinner and longer products from slab

Shape rolling hot rolling of structural shapes from billets and

blooms

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Raw
material

Passing
through
Rolls

Start with a raw material in some form, typically long

dimension, either hot or cold
Hot rolled products such as sheets, plates, bars and
strips serve as input materials
Reduces thickness, change cross-section by
compressive forces
Converts metal ingots to simple stock member, i.e.
blooms, slabs and billets using cylindrical rolls

Desired
shape

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Slab

Billet

Bloom

Rod

A semi finished
steel product
intermediate
between ingot
and plate
Roughly 50150mm thick,
600-1500mm
wide

A semis finished,
hot rolled or
contimuous cast
metal product
Rectangular
cross section
more than
155mm x
155mm

A solid semi
finished, hot
rolled or
continuous cast
metal product of
uniform section
Rectangular with
rounded corners
and cross
section up to
155mm

A solid round
wrought
product, long in
relation to its
cross section
Commonly
drawn into wire
products or used
to make bolts
and nails

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Source:
Prof. Madya Mohd Yusuff Mohd,
Manufacturing Processes Course Manual 1A, 2009