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Lecture 2

The document discusses various metal forming processes including bulk forming processes like rolling, forging, and extrusion as well as sheet metal forming processes like deep drawing, stretching, and bending. It provides examples of products from different processes and classifications based on temperature. Specific processes like forging, extrusion, drawing, rolling, shearing, punching, deep drawing, and bending are explained.

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Ashutosh
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5 views

Lecture 2

The document discusses various metal forming processes including bulk forming processes like rolling, forging, and extrusion as well as sheet metal forming processes like deep drawing, stretching, and bending. It provides examples of products from different processes and classifications based on temperature. Specific processes like forging, extrusion, drawing, rolling, shearing, punching, deep drawing, and bending are explained.

Uploaded by

Ashutosh
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Metal Forming Processes

An overview
Forming of cast products
Classification of forming processes

• Bulk forming processes

Ex: Rolling, Forging, Extrusion, Drawing etc.

• Sheet metal forming processes

Ex: Deep drawing, Stretching, Bending etc.


Products of Bulk Forming Processes
Products of Sheet Metal Forming
Classification of Metal Forming Processes

Based on the temperature of working:


 Cold working : < 0.3 Tm
 Warm Working: 0.3-0.5 Tm
 Hot working: above 0.5 Tm
Forging
• Pressing or repeated hammering of metal
between two dies.
• Open die forging and closed die forging

Video Upsetting
Video open die
forging
Upsetting

•Product examples
• Bolts
• Nails
• Engine valves
Closed die forging

Video Closed
die forging
Forging Machines

Drop hammer Mechanical and Hydraulic Presses


Extrusion of rods
Extrusion of cans
Extrusion of tubes
Rod/Wire Drawing

video

Video Wire drawing


Rolling
Rolling

Video
rolling

Hot rolling

Cold rolling
Sheet Metal Forming
 Flat thin sheet metal blanks are converted into useful
products by applying force using suitable tools.

 Typical shapes produced are:


• parts with single or multiple curves,
• contoured parts with/without flanges,
• cup and box shaped parts with vertical/sloped walls etc.

 Commonly used sheet materials are:


Low carbon steel, Galvanised steel, Stainless steel, Al and
Ti alloys, Special alloys
Shearing
Blanking

A piece of sheet
metal or a blank is
removed from the
primary metal strip
or sheet by shearing.

punch-out: workpiece
remaining strip: scrap
Shearing
Piercing/Punching

punch-out: scrap
remaining strip: workpiece
Deep Drawing video

Bath tubs,
Oil sumps,
LPG cylinders,
Automotive body panels,
Video deep
kitchen sinks, utensils
drawing
Stretch forming

Aircraft parts of large radius of curvature, Cups


with hemispherical bottom, Complex automobile
body panels.
Video hydroforming
Bending Processes
Coining and Embossing

Used to produce coins,


medals, and other Embossing: used
products where exact size for decorative
and fine details are items, wall
required. hangings

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