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Metal Forming

The document provides an overview of bulk deformation processes in metal forming, including forging, extrusion, rolling, and sheet metal working. It explains various techniques such as open-die forging, impression-die forging, and different types of extrusion, highlighting their advantages and applications. Additionally, it covers processes like cutting, notching, perforating, and coining, emphasizing the significance of these methods in shaping metallic parts.

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XI B3 ABHIJEET M
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13 views26 pages

Metal Forming

The document provides an overview of bulk deformation processes in metal forming, including forging, extrusion, rolling, and sheet metal working. It explains various techniques such as open-die forging, impression-die forging, and different types of extrusion, highlighting their advantages and applications. Additionally, it covers processes like cutting, notching, perforating, and coining, emphasizing the significance of these methods in shaping metallic parts.

Uploaded by

XI B3 ABHIJEET M
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Metal forming

What is Bulk Deformation?


Metal forming operations - significant shape change by plastic deformation in metallic
parts are referred to bulk deformation processes.

Cylindrical bars and billets, rectangular billets and slabs -plastically


deformed in cold, warm or hot conditions into a desired shape.

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Forging process

Schematic presentations of (a) open-die forging, (b) impression-die


12/20/2022 forging, and (c) flashless forging 5
Forging process
Forging - metallic part is deformed to a final shape with the application of
pressure and with or without the application of heat.

Open Die Forging


The workpiece is compressed between two flat dies facilitating lateral flow of
material without constraint

Impression Die Forging


 The workpiece is compressed between two dies with a cavity or impression
that is imparted to the workpiece.
 The metal flow is constrained within the impression of the
dies. However, the excess material remains as flash.
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Flashless Forging

This is an improved version of Impression-die forging process.

The initial volume of the workpiece is carefully taken so that no excess flash
is produced

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Extrusion

(a) Direct extrusion

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(b) Indirect extrusion
(c) Extrusion using mandrel

Hydrostatic extrusion Impact extrusion.


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 Extrusion - produce long parts of uniform cross-sections.
Extrusion - workpiece material is forced to flow through a die opening
by applying compressive force to produce a desired cross-sectional
shape.
Extrusion processes are also performed at temperature well above the
recrystallization temperature of the workpiece material and at room
temperature, which are referred to as hot and cold extrusion

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In direct extrusion the extruded product moves in the same direction of the
movement of the punch.
 As a result the billet has to overcome the frictional resistance of the
container wall increasing the power requirement

Indirect extrusion - the billet remains stationary inside the container and the
extruded part comes out in the direction opposite to the punch travel.
The power requirement in indirect extrusion is lesser compared to the same
in direct extrusion as the frictional force is absent in indirect absence due to
stationary billet

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Basic advantages of extrusion processes

(1) Extrusion can produce variety of shapes with uniform cross-section.


(2) The grain structure and mechanical strength of workpiece material
are improved in cold and warm extrusion processes.
(4) Wastage of material is the minimum in extrusion processes.
(5) Extrusion can be performed even for relatively brittle materials.

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Rolling
Rolling is a forming operation where cylindrical rolls are used to reduce the
cross sectional area of a bar or plate with a corresponding increase in the
length.

Rolling process is widely used because of high productivity

Rolling processes - Flat rolling that is used to reduce thickness of a


rectangular cross-section.

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Rolling processes
High temperature (above the recrystallization temperature), which is referred to as Hot
Rolling, as well as at room temperature that is referred to as Cold Rolling.

 Hot Rolling is usually performed when large amount of deformation is required while
Cold Rolling is performed for finished sheet and plate stock.

Various structural members, plates and sheets are produced by rolling at very high
productivity although due to high tooling cost, it is economical for large batch size only.

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Roll Forging
This process is used to reduce the thickness of round or flat bar with the
corresponding increase in length. Examples of products produced by this process
include leaf springs, axles, and levers.

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Complex shapes with good mechanical properties can be produced by bulk
deformation processes

Forging – The initial shape is squeezed and shaped between two opposing
dies.

Extrusion – The initial shape is squeezed through a shaped die such that the
cross-section of the deformed part becomes similar to that of the die opening.

Rolling – A slab or plate is squeezed between two rotating rolls to reduce the
height so as to produce thinner shapes like sheets

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Sheet metal working process

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Spring back of sheet metal
• Spring back : Elastic recovery

( This phenomenon observed in rod, wire, bar and sheet metal)

Compensation

• Overbending the part

• Stretch bending in which the part is subjected to tension while being bent also
counters the spring back

• Bending may also be carried out at elevated temperature to reduce spring back.

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Blanking and punching

In punching the metal inside the part is removed,


in blanking, the metal around the part is removed
• Cutting off
 It separates the work material along a straight line in a single line cut.

Cutting off Parting


Parting
When the operation separates the work material along a straight line cut to
a double line cut it is known as parting.

 Cutting off and parting operations are used to separate the workpiece from
the scrap strip.
• Notching – Specified small amount of material is cut from the blank

• Notching is a sheet metal cutting process that involves the removal of


material from a work piece, starting at the edge and cutting inward.

• It helps in fitting different parts


Perforating
• Number of uniformly spaced holes are
punched in a sheet of metal
• The holes may be any size or shape.
• Perforating sheet metal will allow for the
passage of light or fluid material through
the sheet.
• It can often serve in ventilation and
filtration of fluid substances.
• Perforated sheet metal is also used in
structure and machine construction, to
reduce weight and for cosmetic
appearance.
Coining

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 The difference between coining and embossing is that the same

design is created on both sides of the work piece in embossing

 whereas in coining operation, a different design is created on each

side of work piece.

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