1) - Introduction:: Metal Forming Processes
1) - Introduction:: Metal Forming Processes
1) - Introduction:: Metal Forming Processes
1)- Introduction:
• Metal forming can be defined as a non-cutting shaping process in which the metal piece is shaped by plastic
deformation into useful products by applying forces (tension, compression, bending, shear, etc…) on the work-piece to
obtain the required shape.
Bulk deformation processes are generally characterized by significant deformations and massive shape changes
and the surface area to volume of the work is relatively small.
Starting work shapes for these processes include cylindrical billets and rectangular bars.
Mainly cold and hot forming
- Rolling: This is a compressive deformation process in which the thickness of a slab or plate is reduced
by two opposing cylindrical tools called rolls. The rolls rotate so as to draw the work into the gap
between them and squeeze it.
- Forging: In forging, a work-piece is compressed between two opposing dies, so that the die shapes are
imparted to the work. Forging is traditionally a hot working process, but many
types of forging are performed cold.
- Wire drawing: Similar to extrusion, but force is tensile. Reduction of cross section by pulling it
through a die. This process is most commonly used for wire.
b) Sheet metalworking:
Sheet metalworking processes are forming and cutting operations performed on metal sheets, strips, and coils.
The surface area to volume ratio of the starting metal is high.
Sheet metal operations are always performed as cold working processes and are usually accomplished using a
set of tools called a punch and die.
- Bending: Bending involves straining of a metal sheet or plate to take an angle along a
(usually) straight axis.
- Deep and cup drawing: Refers to the forming of a flat metal sheet into a convex or concave
shape, such as a cup, by stretching the metal.
- Shearing: A shearing operation cuts the work using a punch and a die
2)- Forging process:
• Forging is a metal forming process which is carried out by applying a compressive stress higher than the yield strength
of the work metal.
• To reduce the required forging forces (applied stress), heating to a temperature lower than the melting point is
required.
• Two main types of forging: Free forging (hand forging) and die forging.
The metal, in the form of slugs or slabs (with selected dimensions) is forced to fill a
two halves die having the negative shape of the part to be produced. They are either
forged in the cold or hot state according to their strength.
a)- Anvil: The work-piece is to be kept and with the use of a hammer, the worker strike to the
work-piece for changing the shape and size. It is made of Mild steel. It is composed mainly of two
parts:
-The front part of the anvil is called the “HORN”. It is a massive conical part used to shape the
circular sections.
- The rear part is a flat surface with a “PRITCHEL HOLE” that is used to punch holes, or to bend small diameter rods, and
a “HARDY HOLE” to fix the hardy
• It is a heavy block, having dimensions of 500x500x100 mm, or greater, made of ductile cast iron or steel.
• It contains multiple shapes and size holes in it and can insert the work-piece into it and strike it with the
hammer to get shape and size as you want.
c)- Hammers:
• Different weights of hammers are available. For light works, hammers up to 1 Kg weight are used where
as those with more than 1.5 Kg weight are used for heavy works.
• Fullers are forming tools of different shapes used in making grooves or hollows.
• They are often used in pairs; the bottom fuller has a square shank which fits into hardy
hole in the anvil while the top fuller has a handle
• The work-piece is placed on the bottom fuller and the top fuller is placed on the work-
piece and struck with a hammer.
• The top fuller is also used for finishing corners.
e)- Tongs:
• Tongs are used to hold the work-piece. When the work-piece is heated, tongs used to hold it.
f)- Hardies:
• Hardies are used to notch, neck or cut metallic rod. They are made of high strength, high
toughness and wear resistance steels to withstand impacts and wear.
• The square shank of the hardy is placed into the hardy hole on the flat surface of the anvil and
the rod to be cut is placed on the cutting edge and struck with either a hammer or a hammer and a
chisel according to the type and dimensions of the rod.
g)- Chisels:
• Chisel has a cutting edge as the hardy but fitted with a handle. The chisels are made of the same
materials as those of hardies.
• There are two kinds of chisels: - Cold chisel (used for cutting hard metals in cold conditions) - Hot chisel
(used for cutting soft metals in hot conditions) The cutting edge of the hot chisel is much thinner (the
edge is 30o ) than that of the cold chisel (the edge is 60o )
h)- Punches:
• It is a tool and used for punching the work-piece.
2.1.2)- Main hand forging operations:
a)- UPSETTING:
• Upsetting is the process through which the cross-section of workpiece is increased with a
corresponding reduction in length.
• In this process, the work-piece is heated then heavy blow is given by hammer. The swelling of the
work-piece takes place at the hot portion.
b)- PUNCHING A HOLE:
• Punching is the process of producing the holes by forcing the punch through the work-piece.
c)- CUTTING (COLD):
• A long work-piece is cut into several required length.
• Notches is made and chisel is placed over notch then hammered then turn 180o and chisel
place opposite the metal cut-off in two pieces.
d)- NECKING:
e)- FLATTENING :
• The flattening is carried out for leveling and finishing flat surfaces.
f)- SWAGING:
• Swaging is the operation of changing the shape of cross-section of job to some specific
shape such as round, square, hexagonal etc..
• Swaging operation is carried out with pair of swages or by swage block.
Blanking: Blanking involves cutting sheet metal along a straight line in a single step, to separate a piece from
the surrounding stock. The part that is cut out is the desired product, and is called a blank.
• Punching/piercing to make holes in sheet metal: Punching is similar to blanking, except that the cut piece is
scrap, and is called a slug. The remaining stock is the desired product.
2- Bending
• Bending in sheet metalwork is defined as straining of a metal sheet to take a permanent angle along a straight
axis.
• It is forming process causes the sheet metal to undergo the desired shape change by bending without failure
3- Drawing
• Forming of sheet into convex or concave shapes, such as a cup
b)- Blanking
Blanking is an operation of cutting a flat shape from a sheet metal. The part punched out is called
the blank and the remaining sheet is the scrap
c)- Piercing
Piercing is a cutting operation by which various shaped holes are carried out in the sheet metal. In this
operation, the hole is the required operation and the material punched out is the scrap
d)- Lancing
Lancing is a combination of cutting and bending operations. It is the operation of cutting a sheet
metal through part of its length and then bending the cut portion. There is no scrap in this
operation.
e)- Notching
Notching is the cutting operation by which metal pieces are cut from the edge of a sheet
f)- Shaving
Shaving operation is done to cut the edges of the blanked part in accurate dimension. The shaving
operation removes the rough and uneven edges of the blanked part.
g)- Trimming
Trimming operation is done to remove the excess material from the perimeter of a part, such as
trimming the flange from a drawn cup.
g)- Perforating
Perforating is an operation of producing number of holes evenly spaced in regular pattern on
a sheet metal.
h)- Slitting
Slitting is an operation of cutting straight lines in the sheet. No scrap material is produced.
a)- V-bending
In V-bending, a sheet metal is bent between a V-shaped punch and die.
-
Spring back in bending
Spring back is the elastic recovery of the material after unloading of the tool.
Spring back is encountered in all forming operations, but most easily occurs in bending.
Reasons for spring back is that when bending
pressure is removed, elastic energy remains in
bent part, causing it to recover partially
toward its original shape.
Compensation of spring back by:
- Over bending
- Carried out at elevated temperature
c)- Spinning
• Spinning is metal forming process in which an axially symmetric part is gradually shaped over a rotating
mandrel using a rounded tool or roller.
• In the spinning process, the metal blank is clamped against a form block, which is rotated at high speed.
• Three types of spinning:
1. Conventional spinning
2. Shear spinning
3. Tube spinning
1. Conventional spinning
• Practiced by pressing a tool against a circular metal blank.
Used for low production.
• A conventional spinning has a circular blank of flat or
preformed sheet metal is placed and held against a mandrel and
rotated while a rigid tool deforms and shape the material over
the mandrel.
• Spinning tools or spinning rollers are forced against the
rotating blank either by hand or by auxiliary power or both
• Employing a series of axial and radial strokes ,the blank is spun onto the mandrel causing the metal to
flow to the shape of the desired part.
2. Shear spinning
Metal is formed using high shear
forces. Use of automated CNC
machines. Suitable for high
production runs.
3. Tube spinning
• In tube spinning, the thickness of hollow, cylindrical blanks is reduced or
shaped by spinning them on a solid, round mandrel. The reduction in wall thickness results in a longer tube.
• This operation may be carried out externally or internally.
• The parts may be spun forward or backward.
• Forward Tube Spinning:
- Solid Mandrel
- Metal is spun over the mandrel externally.
- External Finishing is obtained
• Backward Tube Spinning:
- Hollow Mandrel
- Metal is spun inside the hollow mandrel.
- Internal Finishing is obtained.
• Applications of Tube Spinning:
- Rocket
- Missile
- Pressure vessels
- Automotive components, such as car and truck Wheels.
d)- High-energy rate forming (HERF)
• Spinning is metal forming process in which an axially symmetric part is gradually shaped over a rotating
mandrel using a rounded tool or roller.
• Processes to form metals using large amounts of energy over a very time.
• Three types of High-energy rate forming:
1. Explosive forming
2. Electro Hydraulic Forming
3. Electromagnetic Forming
1. Explosive forming
• Explosive forming, is distinguished from conventional forming in that
the punch is replaced by an explosive charge.
• Explosives used are generally high–explosive chemicals, gaseous
mixtures
• Use of explosive charge to form sheet (or plate) metal into a die cavity
• Explosive charge causes a shock wave whose energy is transmitted to
force part into cavity
• In the explosive forming process, the sheet metal blank is placed over a die cavity and an explosive charge is
denoated in medium (water) at an appropriate distance from the blank.
• Applications: large parts, typical of aerospace industry
e)- Ironing
• Ironing is metal forming process that makes wall thickness of cylindrical
cup more uniform.
• Examples: beverage cans and artillery shells
f)- Embossing
• Embossing is metal forming process that is used to create
indentations in sheet such as raised (or indented) lettering.