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IE 2521

Manufacturing Processes I
Ch. 4
(Principles of Metal Forming processes)
by
Ali Abd El-Aty, ​PhD, MASME, FISME
Assistant Professor,
Mechanical Engineering Department
Faculty of Engineering-Kharj
Prince Sattam Bin Abdulaziz University
2023-2024
 Ch. 4: Principles of Metal Forming processes 2

1. Overview of Metal Forming

Independent Variables in Metal Forming Dependent Variables in Metal Forming
Ch. 4: Principles of Metal Forming processes 3

1. Overview of Metal Forming

 Ch. 4: Principles of Metal Forming processes 4

1. Overview of Metal Forming

Classification of Metal forming processes:
 Ch. 4: Principles of Metal Forming processes 5

1. Overview of Metal Forming

Bulk Deformation
Rolling. Extrusion.
This is a compressive deformation process in This is a compression process in which the
which the thickness of a slab or plate is work metal is forced to flow through a die
reduced by two opposing cylindrical tools opening, thereby taking the shape of the
called rolls. The rolls rotate to draw the work opening as its own cross section.
into the gap between them and squeeze it.
Ch. 2: Fundamentals of Metal Forming 6

1. Overview of Metal Forming

Bulk Deformation
Ch. 2: Fundamentals of Metal Forming 7

1. Overview of Metal Forming

Bulk Deformation
Ch. 2: Fundamentals of Metal Forming 8

1. Overview of Metal Forming

Bulk Deformation
Ch. 2: Fundamentals of Metal Forming 9

1. Overview of Metal Forming

Bulk Deformation
 Ch. 4: Principles of Metal Forming processes 10

1. Overview of Metal Forming

Bulk Deformation
Forging. Drawing.
In forging, a workpiece is compressed In this forming process, the diameter of a
between two opposing dies, so that the die round wire or bar is reduced by pulling it
shapes are imparted to the work. Forging is through a die opening.
traditionally a hot working process, but many
types of forging are performed cold.
Ch. 2: Fundamentals of Metal Forming 11

1. Overview of Metal Forming

Bulk Deformation
Ch. 2: Fundamentals of Metal Forming 12

1. Overview of Metal Forming

Bulk Deformation
Ch. 2: Fundamentals of Metal Forming 13

1. Overview of Metal Forming

Bulk Deformation
Ch. 2: Fundamentals of Metal Forming 14

1. Overview of Metal Forming

Bulk Deformation
Ch. 2: Fundamentals of Metal Forming 15

1. Overview of Metal Forming

Bulk Deformation
 Ch. 4: Principles of Metal Forming processes 16

1. Overview of Metal Forming

Sheet Metal Forming
• Sheet metal forming 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; thus, this ratio
is a useful means to distinguish bulk deformation from sheet metal processes.

• Press working is the term often applied to sheet metal operations because the machines used
to perform these operations are presses (presses of various types are also used in other
manufacturing processes). A part produced in a sheet metal operation is often called a
stamping.
• Sheet metal operations are always performed as cold processes and are usually accomplished
using a set of tools called a punch and die.
 Ch. 4: Principles of Metal Forming processes 17

1. Overview of Metal Forming

Sheet Metal Forming
Shearing.
Bending.
This process seems somewhat out-of-place in
Involves straining of a metal sheet or plate to
a list of deformation processes, because it
take an angle along a (usually) straight axis
involves cutting rather than forming. A
shearing operation cuts the work using a
punch and die.
Ch. 2: Fundamentals of Metal Forming 18

1. Overview of Metal Forming

Sheet Metal Forming
Ch. 2: Fundamentals of Metal Forming 19

1. Overview of Metal Forming

Sheet Metal Forming
Ch. 2: Fundamentals of Metal Forming 20

1. Overview of Metal Forming

Sheet Metal Forming
 Ch. 4: Principles of Metal Forming processes 21

1. Overview of Metal Forming

Sheet Metal Forming
Drawing (Deep or Cup).
• In sheet metalworking, drawing refers to
the forming of a flat metal sheet into a
hollow or concave shape, such as a cup, by
stretching the metal. A blank holder is used
to hold down the blank while the punch
pushes into the sheet metal, as shown in
the Figure.
• To distinguish this operation from bar and
wire drawing, the terms cup drawing or
deep drawing are often used.
Ch. 2: Fundamentals of Metal Forming 22

1. Overview of Metal Forming

Sheet Metal Forming
Ch. 2: Fundamentals of Metal Forming 23

1. Overview of Metal Forming

Sheet Metal Forming
 Ch. 4: Principles of Metal Forming processes 24

2. Anisotropy of Sheet Metals

• The variation of the deformation behavior of metals • Experiments show that r depends on the in-
with direction is assessed anisotropy coefficient. plane direction.
• This coefficient is determined by uniaxial tensile
tests on sheet specimens in the form of a strip.
Ch. 4: Principles of Metal Forming processes 25

2. Anisotropy of Sheet Metals

• A measure of the variation of

normal anisotropy with the
angle to the rolling direction is
given by planar anisotropy :
Ch. 4: Principles of Metal Forming processes 26

3. Total System in Forming Processes

 Ch. 4: Principles of Metal Forming processes 27

4. Friction and Lubrication in Metal Forming

• In most metal forming processes, friction is undesirable for the following reasons:
➢ Metal flow in the work is retarded, causing residual stresses and sometimes defects in the
product.
➢ Forces and power to perform the operation are increased,
➢ Tool wear can lead to loss of dimensional accuracy, resulting in defective parts and
requiring replacement of the tooling.
• If the coefficient of friction becomes large enough, a condition known as sticking occurs.
Sticking in metalworking (also called sticking friction) is the tendency for the two surfaces in
relative motion to adhere to each other rather than slide.
 Ch. 4: Principles of Metal Forming processes 28

4. Friction and Lubrication in Metal Forming

• Considerations in choosing an appropriate • Lubricants used for cold working
metalworking lubricant include: operations include mineral oils, fats and
(1) type of forming process (rolling, forging, sheet fatty oils, water-based emulsions, soaps,
metal drawing, and so on), and other coatings.
(2) whether used in hot working or cold working, • When lubricants are used in hot
(3) Work material, working, they include mineral oils,
graphite, and glass. Molten glass
(4) chemical reactivity with the tool and work becomes an effective lubricant for hot
metals (it is generally desirable for the lubricant to extrusion of steel alloys.
adhere to the surfaces to be most effective in
reducing friction), • Graphite contained in water or mineral
oil is a common lubricant for hot forging
(5) ease of application, of various work materials.
(6) toxicity,
(7) flammability,
(8) cost.
 Ch. 4: Principles of Metal Forming processes 29

5. Importance, Applications, and Current issue of Metal Forming industry

Importance of Metal Forming industry Current Issues of Metal Forming industry

Applications of Metal Forming Skills needed for Metal Forming Engineering

 Ch. 4: Principles of Metal Forming processes 30

Questions…