Theory of Metal Forming

Subject code : 10IP662

 Syllabus
Part A:-
1) Basics of Plastic Deformation-TOP
2) Introduction to metal forming
3) Forging Process
4) Rolling Process
Part B:-
5) Extrusion Process
6) Drawing Process
7) Sheet metal working
8) HERF
 Books to Refer
• Mechanical Metallurgy-Dieter G.E
• Manufacturing Process-III by Dr. K.
Radhakrishna
• Manufacturing Process-III by A. C. Niranjan
 Introduction & TOP
•Engineering Materials :- Metals & Alloys,
Polymers, Ceramics, Composites,
Biomaterials, Nanomaterials, Smart materials etc…

•Most important material being Metals & Alloys

Good Strength , Ductility, Toughness
Good Conductivity (thermal, electrical)
Lustrous
Formed easily into required shapes
MANUFACTURING PROCESS- Final Products
defined as conversion of raw materials to
final products

Raw Materials
 Classification of Manufacturing process
(as per DIN 8580)

Primary Dividing Joining Coating Modifying Metal Forming

shaping •Galvanizing Material property •Forging
•Casting •Turning •Welding •Painting •Heat Treatment
•Investment •Milling •Foil wrapping •Rolling
casting •Grinding
•Shell Casting •Extrusion

•Drawing

•Sheet Metal
working
Other way of classifying manufacturing process
would be

• Primary manufacturing – casting, powder metallurgy

etc.
Secondary manufacturing-forging, extrusion etc.

• Chipless manufacturing-forging, extrusion etc.

Chip manufacturing- all machining processes

Metal forming is a chipless-secondary manufacturing

process.
As per DIN 8582 Metal forming is defined as
“Modification of a shape with controlled
geometry”

Forming is the process of obtaining the

required shape and size on the raw material by
Subjecting the material to plastic deformation
through the application of tensile force,
compressive force, bending or shear force or
combinations of these forces.
Some facts,
• Metal forming is the backbone of modern
manufacturing industry
• Hundreds of million tons of metals go through
metal forming processes every year
• As much as 15–20% of GDP of industrialized
nations comes from metal forming industry
• It fulfils a social cause by providing job
opportunities to millions of workers.
Classification of Metal forming:-
• Based on Temperature
Hot Working (T > 0.5Tm),
Cold Working (T< 0.5 Tm) ,
Warm working

• Based on forces applied metal forming can be classified:-

Direct Compression type
Indirect compression type
Tension type
Bending type
Shearing type
Direct Compression type
Indirect Compression type
Tension, Bending & Shearing type
 Brief discussion about different metal
forming techniques
1. Forging
• Forging is the working of metals into a useful
shape by Hammering or Pressing
• It is the oldest of the metalworking arts,
having its origin with the primitive
blacksmiths of biblical times
• Typical parts made by forging techniques are-
crankshafts, connecting rods, hand tools,
machinery & transportation equipments
• Metal forging is done extensively on iron &
steel but can also be carried out on Al, Mg, Ti,
Cu & Ni alloys
• Forging increases the material properties
greatly-by sealing cracks & closing empty
spaces within the metal
• Forging can be done in both hot & cold
conditions-usually done in hot condition
• The manufacturing of forging dies & other
high costs of setting up an operation makes the
production of small quantities of forged parts
an expensive affair.
Press Forging
Connecting rods
Crankshafts
 2.Rolling
• The process of plastically deforming metal by
passing it between rolls is known as rolling
• Most widely used metal working process
leading to high production & close control of
the final product
• Rolling is the most widely used forming
process & it share is roughly 90%
• The material to be reduced is drawn by means
of friction into the 2 revolving roll gap
• The geometry of the product depend on the
contour of the roll gap

• Roll materials are Cast iron, Cast steel &

forged steel because of high strength & wear
resistance requirements

• Hot rolls are generally rough so that they can

bite the work & cold rolls are ground &
polished for good finish
Rolled coils
 3. Extrusion
• Extrusion involves forcing the raw material
through a narrow opening in order to reduce
the dia & increase the length
• Used to produce cylindrical bars, hollow tubes
etc
• Both hot/cold extrusion is possible but as high
forces are required, hot extrusion is done
• Classified as 2 types- direct extrusion &
indirect extrusion process
• Excellent surface finish, complex cross
sections are possible
• Extrusion was first used to make lead pipes
• Extrusion ratio= Dia of starting c/s area/Dia of
final c/s area
• Disadvantage of the process is high cost and
high keep up cost
Fire Extinguisher

Shock Absorber
 4. Drawing of Rods, Wires &
Tubes
• This forming technique is done at cold temperature

• Drawing operation involves pulling metal through a

die by means of a tensile force applied to the exit side
of the die

• In extrusion, a compressive force is applied while in

drawing an tensile force is applied

• Electrical wires, cables, tension loaded structure

components are made by drawing
• The reduction in dia of a solid bar or rod by
successive drawing is known as bar, rod or
wiredrawing, depending on the diameter of the
final product
• This process is done cold but plastic
deformation & friction generates heat
• Drawing involves metals which are highly
ductile as it is to done at cold temperature
• As it is cold working process the surface finish
is usually good
Wire Drawing
Tube drawing
5. Sheet Metal Working
• The technique to produce a variety of shapes
from flat sheets of metal at high rates of
production is Sheet Metal Working
• Another operation carried out in cold
condition
• This operation is generally carried out in the
plane of sheet by tensile forces. Hence a low
tensile strength and high ductility is preferred
• The products generally have high surface to
Area ratio
• The technique is classified based upon the type
of forces acting like Shearing, Tension &
Bending types
• Box, Dish, Cup, Cans, tray, funnel are typical
examples of this technique
• Two requirements for the process-Punch & Die
• We have done this in workshop Practise
• Ericsson cupping test is carried out to check the
ability of the material to undergo deformation
• Punching (Peircing), Blanking, Notching,
Perforating, Slitting, Lancing, parting, shaving,
trimming, fine blanking etc..
 Bending

Shearing
Piercing
 6. HERF
• High Energy Rate Forming
• The search to produce large complicated
shapes from high strength materials-HERF
• High amount of energy is used in a fraction of
second (10-4 sec, while conventional it is 10-1,
10-2 sec)
• Sources of energy could be detonation of
explosives
• Here, energy is released at such a high rate
that local deformation occurs before the
energy can be dissipated through the
deformed material
• Only those materials having high toughness
with strain rate can be easily formed using
HERF
Explosive forming
 Outcomes of TMF
This course aims to
• Provide fundamental knowledge of
conventional metal forming processes
• Basic background of different forces required
for deformation is discussed
• Advantages & disadvantages of processes are
learnt so that selection of metal forming
processes becomes efficient
• Moreover defects during and after the process is
discussed for prevention