Understanding the processes of hot working and cold working

is essential in metal fabrication, as they significantly influence

the mechanical properties and applications of metals.​

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INTRODUCTION

Hot Working involves deforming metals at temperatures above their recrystallization point.
At these elevated temperatures, metals become more malleable, allowing for significant shape
changes without causing strain hardening. Common hot working techniques include hot rolling,
forging, extrusion, and hot drawing. The primary advantage of hot working is the ability to produce
large deformations with relatively low forces, resulting in refined grain structures and improved
mechanical properties.​
Cold Working, on the other hand, refers to deforming metals below their recrystallization
temperature, typically at or near room temperature. This process increases the strength and
hardness of the metal through strain hardening but reduces its ductility. Cold working techniques
include rolling, forging, drawing, bending, and extrusion.

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Hot Working Process
Hot working refers to the process of deforming metals above their
recrystallization temperature, typically at more than 0.6 times their
melting temperature. At this high temperature, metals become soft
and malleable, allowing them to be shaped easily without
developing significant internal stresses or strain hardening.
Advantages of Hot Working:
Better ductility and workability
Low force requirements for shaping
Refinement of grain structure, leading to improved mechanical properties
Elimination of defects such as porosity and inclusions
No strain hardening (which means the metal does not become brittle after
deformation)
Disadvantages of Hot Working:
Poor surface finish due to oxidation and scale formation
Less precise dimensional control due to thermal expansion
Requires high energy for heating
1. Hot Rolling
Hot rolling is the most widely used hot working process. In this method, metal is passed between rollers while
being above its recrystallization temperature.
Process:
The metal is heated to a temperature above its recrystallization point (typically between 900°C - 1300°C for
steel).
It is then passed between two rotating rollers, which compress and elongate the material.
The thickness of the metal reduces while its length increases.
The process continues until the desired shape and thickness are achieved.
Applications:
Used to manufacture steel plates, beams, pipes, railway tracks, and bars.
Common in automobile frames, bridges, and industrial machinery.
2. Hot Forging
Hot forging involves hammering or pressing a metal workpiece into a desired shape while it is hot.
Process:
The metal is heated to between 950°C - 1250°C (for steel) before deformation.
It is then hammered, pressed, or squeezed between dies or anvils.
The force applied helps to rearrange the internal grain structure, making the metal stronger.
Types of Forging:
Open-Die Forging – Metal is hammered freely between two dies (used for large, simple shapes).
Closed-Die Forging (Impression Die) – Metal is pressed into a shaped die cavity (used for precision parts like
crankshafts).
Applications:
Used for aerospace, automotive, and industrial components like gears, shafts, and connecting rods.

3. Press Forging
Press forging is similar to hot forging but uses continuous pressure rather than repeated hammering.
Process:
A workpiece is heated and placed between two dies.
A hydraulic or mechanical press applies steady pressure instead of multiple hammer blows.
The force deforms the metal uniformly into the desired shape.
Advantages:
Produces stronger and more uniform parts than impact forging.
Better for large, complex shapes.
Suitable for high-volume production.
Applications:
Used in automotive parts, industrial machinery, and heavy equipment components.

4. Drop Forging
Drop forging involves shaping metal using a repeated impact force from a heavy hammer.
Process:
The heated metal is placed in a die.
A hammer drops from a height and strikes the metal multiple times.
The impact forces the metal into the die shape.
Types of Drop Forging:
Gravity Drop Forging – The hammer drops using only gravity.
Power Drop Forging – Uses additional air pressure or hydraulics to increase force.
Applications:
Common in hand tools, wrenches, and crankshafts.
Used in aircraft and shipbuilding industries.
5. Hot Extrusion
Hot extrusion is a process where heated metal is forced through a die to create a continuous shape.
Process:
The metal is heated to between 400°C - 1100°C.
It is then pushed through a shaped die using high pressure.
The material emerges with a consistent cross-sectional shape.
Advantages:
Produces complex shapes with high precision.
Enhances material properties by improving grain structure.
Reduces waste material compared to machining.
Applications:
Used for pipes, tubes, window frames, and automotive parts.
Common in aluminum, copper, and steel extrusion industries.
6. Hot Drawing
Hot drawing is a metal-shaping process where metal is stretched through a die
to reduce diameter and increase length.
Process:
The metal is heated above recrystallization temperature.
It is pulled through a die, reducing its thickness while elongating it.
This process improves tensile strength and surface finish.
Applications:
Used to make wires, rods, tubes, and cables.
Common in electrical wiring and suspension cables
Cold Working Process
Cold working involves shaping metal at room temperature or below
its recrystallization point. This process enhances strength
through strain hardening but reduces ductility.

Common Cold Working Techniques:

Cold Rolling – Metal is compressed between rollers to improve
strength and finish.
Cold Forging – Metal is shaped under high pressure without
heating.
Cold Extrusion – Used to make seamless tubes, cans, and complex
profiles.
Bending & Stamping – Used for sheet metal fabrication and
structural parts.
Cold Rolling
One prevalent cold working method is cold rolling, where metal
sheets or strips are compressed between rollers at room
temperature. This process not only enhances the metal's
strength through strain hardening but also improves its surface
finish and dimensional accuracy. However, excessive cold rolling
can lead to brittleness, necessitating subsequent annealing to
restore ductility.

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Cold Forging
Another cold working technique is cold forging, which involves shaping metal by
applying compressive forces using dies and hammers without preheating the
material. This method increases the strength of the metal through strain
hardening and is commonly used for producing components like bolts and
screws. Ulbrich

Cold Extrusion
Cold extrusion is a process where metal is forced through a die to produce
objects with a fixed cross-sectional profile. Performed at room temperature, cold
extrusion results in products with excellent surface finish and dimensional
accuracy, commonly used in manufacturing aluminum cans and collapsible tubes.
Bending
Bending is a cold working process that involves deforming metal along a
straight axis to form a desired angle or shape. Techniques such as roll
forming, tube bending, and angle bending are employed to create
components like metal frames and enclosures. Ulbrich

Point To Note :-
It's important to note that while cold working enhances strength and
hardness, it also increases internal stresses and decreases ductility. To
alleviate these effects, a heat treatment process known as annealing is
often employed. Annealing involves heating the cold-worked metal to a
specific temperature and then cooling it, which helps to restore ductility
and reduce hardness. Ulbrich
Key Differences Between Hot And Cold Working
Feature Hot Working Cold Working
Temperature Above recrystallization Below recrystallization
Material Strength No strain hardening Increases strength
Ductility High Lower
Less precise, rough Higher precision, smooth
Precision & Finish
surface finish
Energy Requirement High (for heating) Lower