Advanced Manufacturing Process by K.A

Prof. K.A.
Patil
JIT COE , Nashik
kameshmech20@gmail.com
Unit I: Metal Forming

1.1Roll forming, 1.2 High velocity hydro forming, 1.3 High velocity Mechanical Forming, 1.4 Electromagnetic forming, 1.5 High
Energy Rate forming (HERF), 1.6 Spinning ,1.7 Flow forming, 1.8 Shear Spinning
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1.1 Roll Forming

Rolling is the process in which the metals and alloys are plastically deformed into semi finished or finished
condition by passing these between circular or contoured rotating cylinders (rolls) the metal is drawn into the
opening between the rolls by frictional forces between the metal and roll surface
Rolling methods used in the scope of remachining or finish machining are limited to the area of cold
forming and are characterized in that only the rim zone of the component is plastically deformed.
Different rolling methods and machines have been developed for the manufacture of rotationally
symmetrical components with a profiled surface.
The most common rolling methods used in remachining and finish machining are profile rolling, thread
rolling and surface fine rolling which will be described in detail in the following,
These methods are subdivided in according to the following categories
kinematics (longitudinal, cross and skewed rolling):
roll geometry (flat and profile rolling) and
workpiece geometry (solid and hollow profile rolling).
The concepts of cross, skewed and longitudinal rolling describe the main forming and lay directions
between the tool and workpiece axes. In longitudinal rolling, the tool moves along the workpiece axis, in cross
rolling transversely to this axis. In skewed rolling, the tool axes are fixed at a certain angle oblique to the
workpiece axis. Rolling itself is counted among the compressive forming processes, i.e. the plastic forming action
is induced largely by a compressive stress.
Examples of Roll Forming:
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Advanced Manufacturing process
UNIT 1 : METAL FORMING
Prof. K.A.Patil
JIT COE , Nashik
Rolling of Tooth Profiles: Both rolling-off and moulding processes are used for manufacturing tooth profiles
through cold rolling. In the rolling-off process, the tooth profile is produced by means of the relative rolling motion
between a tool set derived from a reference profile and the workpiece
Thread Rolling: In thread rolling, the material rises to the flanks of the moulding tool as the tool penetrates the
workpiece, tending to go more above than between the already rolled paths. Especially in sharp threads, this can
lead to the formation of seams, which can reach up to 20 % of the thread depth. Hard material form deeper seams
than soft materials. However, seams cause absolutely no reduction in the load capacity of the threads
The trend which began in 1945 of manufacturing threads using largely chipless processes is mainly the
result of the following advantages of thread rolling in contrast to thread cutting:
high accuracy coupled with high
unsanded smooth surfaces of the rolled threads
increased material strength in the thread flanks
increased fatigue strength
reduced notch sensitivity
savings on material due to the thread dimension in the premachining stage being smaller than the desired
outer thread diameter
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Prof. K.A.Patil
JIT COE , Nashik
Surface Fine Rolling: Surface rolling is a process with which machined workpieces made of deformable materials
are finished with the aid usually of multiple hardened, high-precision machined rolling elements, such as rollers or
balls, under a material-dependent rolling force, and is used to improve surface quality, dimensional accuracy and
strength properties.
Smooth Rolling: The pressure of the smoothing rolls induces a forming of the workpiece which smoothes out the
roughness profile. Smooth rolling is used to create surfaces with low roughness heights and a high profile bearing
length ratio, with the macrogeometric shape of the workpiece remaining ideally unchanged. The method is used to
improve sliding, wear and corrosion properties of sliding components, such as bearing journals, valve stems, piston
rods and sliding guides. It is applied as a pre-machining process for cylindrical workpieces intended for hardchrome plating. Both inner and outer surfaces can be smooth rolled.
Hydrostatically mounted smooth rolling tool

The rolling tool can be equipped with steel or ceramic rolling balls. Steel balls are used for smooth rolling
soft materials, ceramic balls for hardened and hardmachined workpieces. Smooth rolling hardened surfaces, i.e.
hard smooth rolling, can be used to reduce the surface roughness by half and to considerably increase the bearing
contact area ratio.
Sizing Rolling: Whereas with large material diameters the application of rolling as a finishing method is limited to
smooth rolling, as the diameter changes lie in the range of the starting roughness height, soft workpieces with small
diameters (d\20 mm) allow for a diameter change which goes way beyond this measure (d & 0.1 mm). This is then
referred to as sizing rolling. With this process, workpieces with a diameter of 3 mm can be taken from tolerance
quality IT 9IT 5. Roundness errors of the pre-machined workpieces are similarly reduced (to ca. 11.5 lm).
Deep Rolling: Typical components suited to deep rolling are hubs, knuckles, stepped shafts and crankshafts. In the
case of crankshafts, for example, increases in fatigue limit of over 100 % can be achieved by deep rolling the
grooves at the bearings.
Fig.: Deep rolling of a turbine blade
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Prof. K.A.Patil
JIT COE , Nashik
In the process illustrated, a turbine bladei.e. a thin-walled workpiece with a free-formed surfaceis
subjected to a deep rolling operation in the area of the inlet edge. The deep rolling tool has two opposing
hydraulically activated pistons with hydrostatically mounted balls which act on the blade from both sides. This
construction both allows for the compensation of rolling forces and prevents the deflection of the thin-walled
workpiece.
In deep rolling, the goal of increasing the fatigue limit is essentially achieved by means of three factors:
the removal of micro-notches on the workpiece surfaces,
the strain hardening of the surface zone and
the introduction of residual compressive stress into the workpiece surface zone which superimpose the load
stresses, thus reducing the material stress in the tensile area.
Tube Rolling:
FRP tubes can be fabricated from prepreg sheets by a rolling technique , shown in Figure . Such tubes are
used in bicycle frames and space trusses. In the process, a precut prepreg sheet is wrapped around a cylindrical
mandrel several times to obtain a tube wall of multiple sheet thicknesses. The rolled sheets are then encased in a
heat-shrinking sleeve and oven cured. As the sleeve contracts, entrapped gases are squeezed out the ends of the
tube.When curing is complete, the mandrel is removed to yield a rolled FRP tube. The operation is simple, and
tooling cost is low. There are variations in the process, such as using different wrapping methods or using a steel
mold to enclose the rolled prepreg tube for better dimensional control.
Materials Used in Rolling Processes: Any plastically deformable material can be rolled. For rolling tooth profiles
according to the rolling-off principle, all alloyed and unalloyed carbon steels . For the Grob method of profile
rolling, steels with less than 9 % elongation at fracture and tensile strengths Rm[1; 200 MPa provide limit values
with respect to economical tool life. Materials used in thread rolling should exhibit over 5 % elongation at fracture
and tensile strengths Rm \ 1; 200 MPa: Structural and case-hardening steels, stainless steels and heat-treatable
steels are thus appropriate. Other suitable materials are soft brass, copper, light metals and ferritic cast irons, such
as GJS 400 and GJMB 350 [SCHU89, BETH82]. Materials unsuited to profile rolling are brittle materials with low
elongation, such as grey cast iron, hard brass alloys and hardened materials.
Tool Materials Used for Rolling Processes: In recent times, high-speed steel (e.g. S-2-10-1-8) is increasingly
used in the manufacture of profile rolling tools for rolling spline shafts. Newer developments have the aim of using
high-speed steel prepared by powder metallurgy (e.g. ASP 60).
Friction and Lubrication: In thread and profile rolling, unlike chip-removing forming processes, lubricants are
almost exclusively required for their lubricating effect. the abrasive wear of the tools can be reduced by adding a
high-pressure additive in the form of Molykote or colloidal graphite [APEL53, GERL61]. For the purpose of
surface formation in smooth rolling, lubricants can be dispensed with in part. However, molybdenum disulfide
compounds reduce the wear of the smoothing rolls [APEL53]. The use of automatic smooth rolling units also
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Prof. K.A.Patil
JIT COE , Nashik
requires workpiece cooling and the rinsing-off of very fine surface particles in addition to lubrication. If the surface
of the workpiece to be processed exhibits marked pores or high roughness heights, such as those found in cast iron,
a lubricant may not be used, as the lubricant entering the pores can cause changes to the loading condition of the
workpiece possibly leading to failure as a result of the hydrostatic pressure generated during rolling.
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1.2 High Velocity Hydro Forming (HVHF)

Hydro forming: Hydro forming is a manufacturing process in which hollow bodies with complex geometries
can be produced by means of fluid pressure. Hydroforming is a metal fabricating and forming process which
allows the shaping of metals such as steel, stainless steel, copper, aluminum, and brass. This process is a costeffective and specialized type of die molding that utilizes highly pressurized fluid to form metal. Generally there
are two classifications used to describe hydroforming, sheet hydroforming and tube hydroforming. Sheet
hydroforming uses one die and a sheet of metal; the blank sheet is driven into the die by high pressure water on one
side of the sheet forming the desired shape. Tube hydroforming is the expansion of metal tubes into a shape using
two die halves, which contain the raw tube. Hydroforming is used to replace the older process of stamping two part
halves and welding them together. It is also used to make parts both more efficiently by eliminating welding as
well as creating complex shapes and contours. Parts created in this method have a number of manufacturing
benefits including seamless bonding, increased part strength, and the ability to maintain high-quality surfaces for
finishing purposes. When compared to traditional metal stamped and welded parts, hydroformed parts are
lightweight, have a lower cost per unit, and are made with a higher stiffness to weight ratio. The processes can also
be utilized in the single stage production of components; saving labor, tools, and materials.
There are two types of hydro forming:
1) Tube hydro forming
2) Sheet hydro forming
Tube hydro forming:
1) Used when a complex shape is needed.
2) A section of cold-rolled steel tubing is placed in a closed die set.
3) A pressurized fluid is introduced into the ends of the tube.
4) The tube is reshaped to the confine of the cavity.
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Prof. K.A.Patil
JIT COE , Nashik
Sheet hydro forming:

Various types of sheet hydroforming operations, specifically rubber forming and rubber diaphragm
forming, have been used for years in the aircraft industry. Sheet hydroforming is well-suited for prototyping and
low-volume production, which are predominant in the aerospace industry.
Recently, however, sheet hydroforming is garnering special attention in the automotive industry for the
following applications:
Forming alloys with relatively low formability, such as the aluminum alloys and high-strength steels
Low-volume (niche applications) and prototype production
Basics of Sheet Hydroforming:

1)
2)
3)
Sheet steel is forced into a female cavity by water under pressure from a pump or by press action.
Sheet steel is deformed by punch, which acts against pressure.
Sheet hydro forming provides a work harder as the steel is forced against the blanks.
The application of sheet hydroforming is expected to increase during the next decade. While the process has a
disadvantage, namely the low cycle times, it offers many advantages for automotive applications. Some include:
Obtaining greater draw depths with better strain distribution.

Drawing complex shapes in one press cycle.
Reducing die costs because one die is used.
Obtaining excellent finish of the sheet surface exposed to the medium.
High Velocity Hydro Forming

High Velocity Hydro Forming was studied fairly and extensively between about 1950 to 1970.
High Velocity Hydro Forming involves imparting a high kinetic energy to the work piece by accelerating it
to a high velocity, before made it is made to hit the appropriate die.
In these type of forming process, large amount of energy applied for a very short interval of time.
Many metals tends to deform more readily under extra fast application of load which make these processes
useful to form large size parts out of most metals including those which are otherwise difficult to form.
Deformation velocity range : The velocities of conventional machines are generally lowered by 1000 times
of high velocity forming systems.
Manufacturing Costs: Hydroforming versus Deep Draw Stamping
Tooling - With low volume runs, tooling is often the most important cost consideration. With
hydroforming, a male die, or punch, and a blank holding ring are the only tools required as the rubber
diaphragm and pressurized forming chamber act as the female die. As a result, hydroforming tooling is
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Prof. K.A.Patil
JIT COE , Nashik
typically 50% less expensive than matched die tooling. With hydroforming, most punches are made from
cast iron as opposed to the hardened tool steels used for match die drawing punches. Finally, hydroforming
tools are easily mounted and aligned, making set-ups fast and efficient.
Development Costs - Proto-typing is often a necessary step in the manufacturing process. Changes in
material type or wall thickness specifications can typically be accommodated with hydroforming without
creating a need for new tooling.
Reduced Press Time - Complex parts requiring multiple press cycles in matched die operations can be
drawn in a single hydroforming cycle. Hydroforming presses frequently achieve reductions of 60-70%
compared to 35-45% for conventional matched die presses.
Finishing Costs - Aerospace, medical and commercial cookware applications often demand parts with
outstanding surface finishes. Unlike matched die metal forming, which can leave scratches and stretch
lines, the flexible diaphragm utilized in hydroforming eliminates surface blemishes, reducing the need for
costly finishing processes like buffing.
Materials used for hydroforming: Mild Steel, Hard Steel, Stainless Steel, Aluminum Alloys, Copper Tubes
Advantages of HVHF:
1) Forming complex parts with close tolerances, from alloys that may not be formable by conventional
forming(Stamping).
2) Material does not show spring back effect(differential elastic strain through the thickness of a sheet metal
while forming).
3) Die costs are low.
4) The production cost of components by such process is low.
Disadvantages(Limitations) of HVHF:
1) Skilled persons are required.
2) Process is not suitable for highly brittle material.
Applications: Hydroforming process recently draws attention of automotive industries due to its advantages like
the increased strength, weight reduction, improved quality and reduced tooling cost. It can produce wide range of
products including subframes, camshafts, radiator frames, front and rear axles, crankshafts, seat frames and exhaust
manifolds with cheaper production cost by reducing overall number of processes . The advantages of hydroformed
parts include the increased strength to weight, weight reduction through more efficient section design, reduction of
number of parts and subassemblies, improved quality of formed components in terms of dimensional stability and
repeatability, and reduced tooling developing costs.
1) Deep recessing(Cup Cone).
2) Shallow recessing(Beaded Panels, Irregular Shapes).
3) Bulged Parts(Tubes, Nozzles, Ducts).
4) Plane Contoured Curves(Singly Curved, Compound Curvature, reversely Curved).
.
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Prof. K.A.Patil
JIT COE , Nashik
1.3 High Velocity Mechanical Forming (HVMF)

High-velocity metal forming was the focus of much research approximately 30 years ago. It appears that
this technology responds well to many of the challenges facing sheet metal forming today: formability is enhanced,
springback is minimized, and die tryout time should be minimized.
The HVMF manufacturing processes are preferred when High Energy Rate Forming methods are applied
for mass production in the plant. High Velocity Metal Forming (HVMF) is an exciting breakthrough in metal
forming technology with a goal of adding more precision to the metal forming process, increasing processing
speed, and reducing cost in terms of equipment and processing.
Benefits of HVMF
The high impact improves surface finish and enhances formability resulting in a crisper, more defined part
Wrinkling is suppressed allowing for a deeper draw while maintaining a uniform thickness in the part
The opportunity to use lower cost materials because of the improved formability of the process
Reduced number of operations
Less tooling by using only one die
10%-60% more elongation without tearing
Allows welding of dissimilar materials
Less reliance on lubricants
No hazardous chemicals for cleanup
No electromagnetic emissions
Controlled spring back
Lower energy cost by using less power
Metal formability is improved providing a much more consistently formed part
High rate mechanical presses: According to the drive mechanism high-rate mechanical forming machines can be
subdivided into
1) pneumatically driven machines,
2) explosively driven machines, and
3) electromagnetically driven machines.
Pneumatically driven machines
Now let us take a pneumatic mechanical and combustion techniques that is used for forming processes.
These are preferred when the high energy rate forming methods are applied to mass production within a
plant.
In a pneumatic mechanical press, one portion of the forming die is attached to the stationary bolster of the
press bed and the other to the movable piston.
Low pressure gas acts on the entire bottom area of the piston, holding it up against a small area seal.
High pressure gas is then applied to the other side of the seal and the pressure is steadily increased.
When the force pushing down high pressure on the small area exceeds that pushing up that is low pressure
on the large area, the seal is broken and the entire area of the piston is exposed to high pressure gas.
The piston moves rapidly downwards, bringing the dies into contact.
Internal combustion process operates on the same principles as that of an automobile engine.
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Prof. K.A.Patil
JIT COE , Nashik
A gaseous mixture is exploded within a cylinder causing a piston to be driven downwards in a rapid
fashion.
The upper segment of the forming die is attached to the bottom of the piston.
Internal combustion pistons can produce die velocities up to 50 feet per second and cycle rates upto 60
strokes per minute.
Either single or repeated blows can be used to form a part.
Materials used for Mechanical forming: Mild Steel, Hard Steel, Stainless Steel, Aluminum Alloys, Copper
Tubes
Advantages of HVMF:
1. Forming complex parts with close tolerances, from alloys that may not be formable by conventional
forming(Stamping).
2. Material does not show spring back effect(differential elastic strain through the thickness of a sheet metal
while forming).
3. Die costs are low.
4. The production cost of components by such process is low.
Disadvantages(Limitations) of HVMF:
1. Skilled persons are required.
2. Process is not suitable for highly brittle material.
Applications: Much activity is now devoted to in creasing the amount of aluminum in automobile bodies and
reducing the net weight of cars.' Some of the most signifi- cant problems arise because aluminum is generally
more difficult to form into useful shapes than steel. There are two primary fundamental reasons for this. First, the
forming limits of aluminum are significantly lower than those for steel. One eHect of this is that aluminum is
particularly prone to tearing at bends. This also slows die design and die tryout and places limits on the shapes that
can be fabricated. Second,thickeraluminum sheets are generally required to produce the same strength as in a steel
component because springbackthe elastic recovery that normally takes place after deformationis more
severe, and it is difficult to keep dimensional tolerances. Technologies that can reduce these problems are being
sought
1. Deep recessing(Cup Cone).
2. Shallow recessing(Beaded Panels, Irregular Shapes).
3. Bulged Parts(Tubes, Nozzles, Ducts).
4. Plane Contoured Curves(Singly Curved, Compound Curvature, reversely Curved).
.
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Prof. K.A.Patil
JIT COE , Nashik
1.4 Electro Magnetic Forming

The process is also called magnetic pulse forming and is mainly used for swaging type operations, such as
fastening fittings on the ends of tubes and crimping terminal ends of cables. Other applications are blanking,
forming, embossing, and drawing. The work coils needed for different applications vary although the same power
source may be used.
To illustrate the principle of electromagnetic forming, consider a tubular work piece. This work piece is
placed in or near a coil, see in figure. A high charging voltage is supplied for a short time to a bank of capacitors
connected in parallel. (The amount of electrical energy stored in the bank can be increased either by adding
capacitors to the bank or by increasing the voltage). When the charging is complete, which takes very little time, a
high voltage switch triggers the stored electrical energy through the coil. A high intensity magnetic field is
established which induces eddy currents into the conductive work piece, resulting in the establishment of another
magnetic field. The forces produced by the two magnetic fields oppose each other with the consequence that there
is a repelling force between the coil and the tubular work piece that causes permanent deformation of the work
piece.
Either permanent or expandable coils may be used. Since the repelling force acts on the coil as well the
work, the coil itself and the insulation on it must be capable of withstanding the force, or else they will be
destroyed. The expandable coils are less costly and are also preferred when high energy level is needed.
Magnetic forming can be accomplished in any of the following three ways, depending upon the
requirements.
Coil surrounding work piece. When a tube like part x is to fit over another part y (shown as insert in
Fig.(i)), coil is designed to surround x so that when energized, would force the material of x tightly around
y to obtain necessary fit.
Coil inside work piece. Consider fixing of a collar on a tube like part, as shown in Fig.(ii). The magnetic
coil is placed inside the tube like part, so that when energized would expand the material of the part into
the collar.
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Prof. K.A.Patil
JIT COE , Nashik
Coil on flat surface. Flat coil having spiral shaped winding can also be designed to be placed either above
or below a flat work piece, see in Fig(iii).These coils are used in conjunction with a die to form, emboss,
blank, or dimple the work piece.
Figure : Various applications of magnetic forming process. (i) Swaging, (ii) Expanding, and (iii) Embossing or
blanking.
In electromagnetic forming, the initial gap between the work piece and the die surface, called the fly
distance, must be sufficient to permit the material to deform plastically. From energy considerations, the ideal
pressure pulse should be of just enough magnitude that accelerates the part material to some maximum velocity
and then let the part come to zero velocity by the time it covers the full fly distance. All forming coils fail,
expendable coils fail sooner than durable coils, and because extremely high voltages and currents are involved,
it is essential that proper safety precautions are observed by the production and maintenance personnel.
Advantages:
i) Suitable for small tubes
ii) Operations like collapsing, bending and crimping can be easily done.
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Prof. K.A.Patil
JIT COE , Nashik
iii) Electrical energy applied can be precisely cont rolled and hence the process is accurately controlled.
iv) The process is safer compared to explosive forming.
v) Wide range of applications.
Limitations:
i) Applicable only for electrically conducting materials.
ii) Not suitable for large work pieces.
iii) Rigid clamping of primary coil is critical.
iv) Shorter life of the coil due to large forces acting on it.
Applications:
i) Crimping of coils, tubes, wires
ii) Bending of tubes into complex shapes
iii) Bulging of thin tube
Electromagnetic forming process is capable of a wide variety of forming and assembly operations. It has
found extensive applications in the fabrication of hollow, non circular, or asymmetrical shapes from tubular
stock.
The compression applications involve swaging to produce compression, tensile, and torque joints or sealed
pressure joints, and swaging to apply compression bands or shrink rings for fastening components together. Flat
coils have been used on flat sheets to produce stretch (internal) and shrink (external) flanges on ring and disc
shaped work pieces. Electromagnetic forming has also been used to perform shearing, piercing, and rivettting.
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1.5 High Energy Rate Forming (HERF) Processes

A number of methods have been developed to form metals through the application of large amounts of
energy in a very short time interval. These processes are known as high energy rate forming processes. Many
metals tend to deform more rapidly under the ultra rapid load application rates used in these processes. Principle of
high energy rate metal forming can be explained like this, if we have a ductile material, then this material can be
deformed by working on it at a very faster speed and against a die of the shape required, the material can be shaped
under the pressure of this applied energy.
Principle / important features of HERF processes:

The energy of deformation is delivered at a much higher rate than in conventional practice.
Larger energy is applied for a very short interval of time.
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Prof. K.A.Patil
JIT COE , Nashik
High particle velocities are produced in contrast with conventional forming process.
The velocity of deformation is also very large and hence these are also called High Velocity Forming
(HVF) processes.
Many metals tend to deform more readily under extra fast application of force.
Large parts can be easily formed by this technique.
For many metals, the elongation to fracture increases with strain rate beyond the usual metal working range,
until a critical strain rate is achieved, where the ductility drops sharply.
The strain rate dependence of strength increases with increasing temperature.
The yield stress and flow stress at lower plastic strains are more dependent on strain rate than the tensile
strength.
High rates of strain cause the yield point to appear in tests on low carbon steel that do not show a yield
point under ordinary rates of strain.
Factors affecting HERF Processes
The forming processes are affected by the rates of strain used.
1. The flow stress increases with strain rates
2. The temperature of work is increases due to adiabatic heating.
3. Improved lubrication if lubricating film is maintained.
4. Many difficult to form materials like Titanium and Tungsten alloys, can be deformed under high strain
rates.
Advantages of HERF Processes
1.
2.
3.
4.
5.
6.
Production rates are higher, as parts are made at a rapid rate.

Die costs are relatively lower.
Tolerances can be easily maintained.
Versatility of the process it is possible to form most metals including difficult to form metals.
No or minimum spring back effect on the material after the process.
Production cost is low as power hammer (or press) is eliminated in the process. Hence it is economically
justifiable.
7. Complex shapes / profiles can be made much easily, as compared to conventional forming.
8. The required final shape/ dimensions are obtained in one stroke (or step), thus eliminating intermediate forming
steps and pre forming dies.
9. Suitable for a range of production volume such as small numbers, batches or mass production.
Limitations:
1.
2.
3.
4.
5.
6.
7.
8.
Highly skilled personnel are required from design to execution.

Transient stresses of high magnitude are applied on the work.
Not suitable to highly brittle materials
Source of energy (chemical explosive or electrical) must be handled carefully.
Governmental regulations/ procedures / safety norms must be followed.
Dies need to be much bigger to withstand high energy rates and shocks and to prevent cracking.
Controlling the application of energy is critical as it may crack the die or work.
It is very essential to know the behavior or established performance of the work metal initially.
Applications:
1. In ship building to form large plates / parts (up to 25 mm thick).

2. Bending thick tubes/ pipes (up to 25 mm thick).
3. Crimping of metal strips.
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Prof. K.A.Patil
JIT COE , Nashik
4. Radar dishes
5. Elliptical domes used in space applications.)
6. Cladding of two large plates of dissimilar metals.
In these forming processes large amount of energy is applied for a very short interval of time. Many metals
tend to deform more readily under extra fast application of load which make these processes useful to form large
size parts out of most metals including those which are otherwise difficult to form.
The parts are formed at a rapid rate, and thus these processes are also called high velocity forming
processes. There are several advantages of using these forming processes, like die costs are low, easy maintenance
of tolerances, possibility of forming most metals, and material does not show spring-back effect. The production
cost of components by such processes is low. The limitation of these processes is the need for skilled personnel.
Die Materials:
Different materials are used for manufacture of dies for explosive working, for instance, high strength tool
steels, plastics, concrete etc. Relatively low strength dies are used for short run items and for parts where close
tolerances are not critical, while for longer runs, high strength die materials are required. Kirksite and plastic (fiber
glass) faced dies are employed for light forming operations requiring low pressures and used for fewer parts.
Ductile iron is used in high pressures and for mass production, whereas concrete is used for medium pressure and
large part requirements.
There are three main high energy rate forming processes:
Explosive Forming,
Magnetic Forming,
Electro Hydraulic Forming.
Explosive Forming
1. Explosive forming, is distinguished from conventional forming in that the punch or diaphragm is
replaced by an explosive charge.
2. The explosives used are generally high explosive chemicals, gaseous mixtures, or propellants.
3. A punch in conventional forming is replaced by an explosive charge.
4. Explosives used can be: High energy chemicals like TNT, RDX, and Dynamite, Gaseous mixtures,
Propellants
5. There are two techniques of high explosive forming:
stand off technique
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Prof. K.A.Patil
JIT COE , Nashik
contact technique.
Standoff Technique.:
The sheet metal work piece blank is clamped over a die and the assembly is lowered into a tank filled with
water. The air in the die is pumped out. The explosive charge is placed at some predetermined distance from the
work piece, see in Figure. On detonation of the explosive, a pressure pulse of very high intensity is produced. A
gas bubble is also produced which expands spherically and then collapses. When the pressure pulse impinges
against the work piece, the metal is deformed into the die with as high velocity as 120 m/s.
The use of water as the energy transfer medium ensures a uniform transmission of energy and muffles the
sound of the explosive blast. The process is versatile a large variety of shapes can be formed, there is virtually no
limit to the size of the work piece, and it is suitable for low quantity production as well.
The process has been successfully used to form steel plates 25 mm thick x 4 m diameter and to bulge steel
tubes as thick as 25 mm.
Sequence of underwater explosive forming operations
.(i) explosive charge is set in position
(ii) pressure pulse and gas bubble are formed as the detonation of charge occurs,
(iii) workpiece is deformed, and
(iv) gas bubbles vent at the surface of water
Fig: Standoff Technique

Contact Technique:
The explosive charge in the form of cartridge is held in direct contact with the work piece while the
detonation is initiated. The detonation builds up extremely high pressures (upto 30,000MPa) on the surface of the
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Prof. K.A.Patil
JIT COE , Nashik
work piece resulting in metal deformation, and possible fracture. The process is used often for bulging tubes, as
shown in Fig.
Figure: Schematic illustration of contact technique of explosive forming.

Applications:
Explosive forming is mainly used in the aerospace industries but has also found successful applications in
the production of automotive related components. The process has the greatest potential in limited production
prototype forming and for forming large size components for which conventional tooling costs are prohibitively
high.
Ship building, Radar dish, Elliptical domes in space applications
Advantages;
i) Shock wave is efficiently transmitted through water and energy is transmitted effectively on the work.
ii) Less noise
iii) Less probability of damage to work.
iv) Large and thick parts can be easily formed
v) Economical, when compared to a hydraulic press
Limitations:
i) Optimum SOD is essential for proper forming operation.
ii) Vacuum is essential and hence it adds to the cost.
iii) Dies must be larger and thicker to withstand shocks.
iv) Not suitable for small and thin works.
v) Explosives must be carefully handled according to the regulations of the government.
Electro Hydraulic Forming

Electro hydraulic forming (EHF), also known as electro spark forming, is a process in which electrical
energy is converted into mechanical energy for the forming of metallic parts. A bank of capacitors is first charged
to a high voltage and then discharged across a gap between two electrodes, causing explosions inside the hollow
work piece, which is filled with some suitable medium, generally water. These explosions produce shock waves
that travel radially in all directions at high velocity until they meet some obstruction. If the discharge energy is
sufficiently high, the hollow work piece is deformed. The deformation can be controlled by applying external
restraints in the form of die or by varying the amount of energy released, see in figure.
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Prof. K.A.Patil
JIT COE , Nashik
Fig. Unrestrained and restrained electro-hydraulic forming process.

Advantages
1. EHF can form hollow shapes with much ease and at less cost compared to other forming techniques.
2. EHF is more adaptable to automatic production compared to other high energy rate forming techniques.
3. EHF can produce small to intermediate sized parts that don't have excessive energy requirements.
Accuracy of parts produced : Accuracy of electro hydraulically formed parts depends on the control of both the
magnitude and location of energy discharges and on the dimensional accuracy of the dies used. With the modern
equipment, it is now possible to precisely control the energy within specified limits, therefore the primary factor is
the dimensional accuracy of the die. External dimensions on tubular parts are possible to achieve within 0.05 mm
with the current state of technology.
Materials formed :Materials having low ductility or having critical impact velocity less than 30 m/s are generally
not considered to be good candidate for EHF. All materials that can be formed by conventional forming processes
can be formed by EHF also. These materials are aluminum alloys, nickel alloys, stainless steels, titanium, and
Inconel.
.
1.6 Spinning
METAL SPINNING is a term used to describe the forming of metal into seamless, axisymmetric shapes by
a combination of rotational motion and force. Metal spinning typically involves the forming of axisymmetric
components over a rotating mandrel using rigid tools or rollers. There are three types of metalspinning techniques
that are practiced: manual (conventional) spinning, power spinning , and tube spinning
The metal spinning manufacturing process is used to produce rotationally symmetrical hollow bodies. The
starting shape of the workpiece is a circular sheet or a pre-shaped hollow body. The wall strengths of the initial and
final shape are almost the same in conventional metal spinning. In the process variants projection straightening and
shear spinning, the wall strength of the starting shape is reduced
Conventional metal spinning has the following shaping functions:
necking and expanding,
creating inner and outer ribs,
neck forming,
thread spinning
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Prof. K.A.Patil
JIT COE , Nashik
Examples of products from metal spinning. The range of components include:

Bases, baskets, basins, and bowls
Bottoms for tanks, hoppers, and kettles
Canopies, caps, and canisters
Housings for blowers, fans, filters, and flywheels
Ladles, nozzles, orifices, and tank outlets
Pails, pans, and pontoons
Cones, covers, and cups
Cylinders and drums
Funnels and horns
Domes, hemispheres, and shells
Rings, spun tubing, and seamless shapes
Vents, venturis, and fan wheels
The equipment for metal spinning is based on lathe technology, with appropriate modifications for the
components that are being formed. Typically, sheet preforms are employed to allow relatively low forming
stresses. Metal spinning can be used to cost-effectively produce single or a small number of parts out of expensive
materials, such as platinum, or large quantities of components of low-cost materials, such as aluminum reflectors.
In this article, the term perform is used to describe the component both before and during metal spinning; other
terms that are sometimes used include workpiece and starting blank.
In manual spinning, a circular blank of a flat sheet, or preform, is pressed against a rotating mandrel using a
rigid tool
Metal spinning is a cold forming process in which the blank metal appears to flow somewhat like a piece of
clay on potters wheel.
Metal Spinning is a term used to describe the forming of metal into seamless, axis sym-metric shapes by a
combination of rotational motion and force. Metal spinning typically involves the forming of axis symmetric
components over a rotating mandrel using rigid tools or rollers.
The Blank sheet metal is rotated about an axis while a form tool is pressed against the part into a chuck shape tool to
form a desired shape.
Lubricants generally need to be used in all metal-spinning operations, regardless of the preform
composition or shape or the type of metal-spinning tools that are used. Lubricants are typically required both
before and during forming. The need for lubrication during spinning depends on the tenacity of the lubricant used
and on the rotational speed of the preform. The lubricant must continue to adhere to the rotating preform during
spinning. Ordinary cup grease is often used. It can be heated to reduce its viscosity, for ease of application. Other
lubricants used for metal spinning include soaps, waxes and tallows, and pigmented drawing compounds; in the
selection of the most suitable lubricant, the ease of removal of the lubricant after forming has to be considered.
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Prof. K.A.Patil
JIT COE , Nashik
Fig. Metal Spinning

Process of Metal Spinning:
1. The external shape of the mandrel corresponds to the internal contour of the part to be produced.
2. The blank is clamped between spinning mandrel and follower on the tailstock spindle.
3. The mandrel , blank and follower are then set in rotation at controlled speeds.
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Prof. K.A.Patil
JIT COE , Nashik
Classification Of Metal Spinning Techniques:
Projection Lengthening
Projection lengthening is used to produce rotationally symmetrical hollow bodies with conical, concave or
convex walls. In the forming process, the wall strength of the starting shape is reduced in such a way that every
volume element of the workpiece is displaced parallel to the axis of rotation. The outer diameters of the starting
and final shape thus remain identical. The spinning roller moves at a corresponding distance parallel to the contour
of the spinning chuck.
Materials which may be used in Spinning Manufacturing:

Aluminum , Brass, Copper, Steel Cold Rolled, Steel Hot Rolled, Stainless Steel
Disadvantages:
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Prof. K.A.Patil
JIT COE , Nashik
Advantages:
Applications:
1.7 Flow Forming

Flow forming is a well known technique to produce cartridge case, rocket nose cones, rocket launcher
casing etc. for defense industry. FLOW forming is gradually used as metal forming process for production of axi
symmetric engineering components in small or medium batch quantities. Flow forming is a locally plastic
deformation applied to manufacture seamless tubes with thin walls and high precision dimensions. That facilitate
customers to optimize design and reduce weight as well as cost, all of these are vital in automobile industries. This
is mainly used for axi-symmetric and hard to deform material like Cu, Mg, Ti etc. alloys.
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Prof. K.A.Patil
JIT COE , Nashik
There basically two strategies have been applied in flow forming process i.e. forward and backward. In
forward flow forming the deformation of tube takes place in the same direction of roller feed and in the backward
flow forming the deformation takes place in the opposite direction of the roller feed
Flow forming is a process whereby a metal blank, a disc or a hollow tube are mounted on a mandrel which
rotates the material to make flow axially by one or more rollers along the rotating mandrel. The major difference
between spinning and flow forming is, in spinning, the thickness reduction is very minor and in flow forming the
variation in thickness can be maintained at different places along axial directions.
In the process of flow forming, there are two forces acting on the circle dish material by each roll, one is
push force another is roll pressure; therefore the material is squeezed deformation.
Tool : Due to the pressures involved in the flow forming process, flow form tools i.e. rollers and mandrels must be
made from hardenable steel that is heat treated and drawn to a temper that makes the tool hard but yet not brittle.
Since the metal is extruded in a rotary fashion rather than stretched over the mandrel, the flow form mandrel will
last for many thousands of pieces, as long as care is taken during setup and the mandrel is stored properly
Materials Used in Flow forming: Stainless Steel, Carbon Steel Maraging Steel Alloy Steel Precipitated Hardened Stainless
Steel Titanium Inconel Hastelloy Brass Copper Aluminum Nickel Niobium
Classification of Flow Forming Process: Forward Flow forming, Reverse Flow Forming
The two types of flow forming are shown in schematically. The difference is according to the direction of
material flow with respect to direction of motion of tool(roller). If both are in same direction, then it is forward
flow forming and if they are in opposite direction, then it is backward flow forming. Forward flow forming is
suitable for long, high precision thin walled components. Backward flow forming is suitable for blanks without
base or internal flange. In backward flow forming the mandrel is unsupported. In both the flow forming processes,
there is no difference in stress and strain rate . Both spinning and flow forming can also be combined to produce
complex components. By rotating mandrel process only cylindrical components can be produced.
Flow forming is an advanced, often net-shape, hot and cold metal-working process for manufacturing
seamless, dimensionally precise tubular and other rotationally symmetric products. The process involves applying
compression to the outside diameter of a cylindrical perform, attached to a rotating mandrel. Compression is
applied by a combination of axial and radial forces using a set of three or four rollers that are simultaneously
moved along the length of the rotating perform, the material flows plastically in both radial and axial directions.
The result is a dimensionally accurate, high quality cylindrical or shaped tubular product having increased
mechanical properties and fine surface finish. The starting blank can be in the form of a sleeve or cup. Blanks can
be produced by spinning, deep drawing or forging plus machining to improve the dimensional accuracy.
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Prof. K.A.Patil
JIT COE , Nashik
Advantages such as an increase in hardness due to an ability to cold work and better surface finish couples with
simple tool de-sign and tooling cost make flow forming a particularly attractive technique for the production of
hydraulic cylinders, and cylindrical hollow parts with different stepped sections.
Advantages
Cost reduction
Reduced cycle times- increased productivity
Assemblies replaced by parts made as a single piece components.
Optimum grain structure.
Elimination of weld seams
Defects in flow forming:
The major defects observed were fish scaling, premature burst, diametral growth, micro cracks and macro cracks.
Applications
Presently this flow forming technology is commercially used in aviation & defense components manufacturing. The potential of this
process has also been explored in other sectors too e.g. to produce thin walled tubes & closed end cylinders for the chemical, nuclear,
food, pharmaceutical, cryogenic, beverage, filtration and printing industries. The main advantage of the process are precise and
accurate production with improved mechanical properties, effective material utilization, chip less production & shorter processing time
and elastic production process are some of the complimentary advantages of flow forming process.
Gas pressure vessels, Airbag pressure vessels, Shock absorbers, Gas Springs, Gear Flanges, Gearbox
Shafts, Conveyor Rolls, Printing Roll
.........................................................................................................................................................................................
1.8 Shear spinning

Power spinning of metals and alloys is also known as shear spinning, because in this method metal is
deformed using high shear forces (up to 3.5 MN, or 800,000 lbf). There are two broad applications of power
spinning: metal cone spinning and metal tube spinning. In cone spinning, the deformation of the metal from the flat
blank is performed in accordance with the sine law, as is described subsequently. Almost all ductile metals can be
shaped using power spinning (provided they have a minimum ductility of ~2%). Products range from small
hardware items made in large quantities (metal tumblers, for example) to large components for aerospace
applications in low volume production. A classic low-productionvolume example of power spinning involved the
Concorde engine compressor shaft , which was formed by a combination of forging and spinning, because this was
more efficient than forging alone. Metal blanks as large as 6 m (20 ft) in diameter have been successfully formed
using power spinning. Conical and curvilinear shapes are most commonly produced from flat (preformed) blanks
by power spinning. Plate stock up to 25 mm (1.0 in.) thick can be power spun at room temperature. Blanks as thick
as 140 mm (5.5 in.) have been successfully spun at elevated temperature.
The most common application of power spinning is for conical shapes. In this variant, the metal is
volumetrically displaced in the axial direction. The metal deformation occurs in accordance with the sine law,
which relates the wall thickness of the starting blank.
23
Prof. K.A.Patil
JIT COE , Nashik
Schematic diagrams of a vertical arrangement employed for power spinning of large-diameter cones
Shear spinning is used to manufacture cylindrical hollow bodies. In one or multiple overruns of the
spinning roller parallel to the axis of rotation of the spinning chuck, the wall strength of the workpiece is reduced,
with the inner diameter usually maintained. However, a circular sheet can also be selected as the starting shape.
Because of the constant volume, the workpiece height stands in direct proportion to the wall strength reduction
With respect to the kinematics of the spinning process, one distinguishes between co-rotating and counter-rotating
processes. Whereas in co-rotating processes, feed and material movement run in the same direction, the material
flow in counter-rotating processes runs in the opposite direction of the tool movement.
The application area of shear spinning can also be expanded to the manufacture of conical, convex and
concave shaped parts. In contrast to projection lengthening, workpieces can be produced with defined wall
strengths by controlling the motion of the rollers.
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Advanced Manufacturing Process by K.A

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Prof. K.A.

Unit I: Metal Forming

1.1 Roll Forming

Examples of Roll Forming:

Hydrostatically mounted smooth rolling tool

Fig.: Deep rolling of a turbine blade

1.2 High Velocity Hydro Forming (HVHF)

Sheet hydro forming:

Basics of Sheet Hydroforming:

Obtaining greater draw depths with better strain distribution.

High Velocity Hydro Forming

1.3 High Velocity Mechanical Forming (HVMF)

1.4 Electro Magnetic Forming

Advanced Manufacturing process

1.5 High Energy Rate Forming (HERF) Processes

Principle / important features of HERF processes:

Production rates are higher, as parts are made at a rapid rate.

Highly skilled personnel are required from design to execution.

1. In ship building to form large plates / parts (up to 25 mm thick).

Fig: Standoff Technique

Figure: Schematic illustration of contact technique of explosive forming.

Electro Hydraulic Forming

Fig. Unrestrained and restrained electro-hydraulic forming process.

Examples of products from metal spinning. The range of components include:

Fig. Metal Spinning

Classification Of Metal Spinning Techniques:

Materials which may be used in Spinning Manufacturing:

1.7 Flow Forming

1.8 Shear spinning

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