Topic 3
Metal Forming &
Shaping Processes
(a) An Overview
Compiled by:
Norliana Mohd Abbas
Sources:
1.
Manufacturing Engineering & Technology 5th Edition, Serope Kalpakjian, Steven
Schmid, Prentice Hall, 2006
2.
Fundamentals of Modern Manufacturing: Materials, Processes and System,
Mikell P. Groover, John Wiley & Sons (Asia), 2007
3.
MYM Handout 2009
Overview
What is Metal Forming?
Material Properties in Metal Forming
Deformation Processes
Plastic Deformation in Metal Forming
Material Behavior in Metal Forming
Temperature in Metal Forming
Friction in Metal Forming
Lubrication in Metal Forming
Selecting Manufacturing Process
What is Metal Forming?
Large group of manufacturing processes in
which plastic deformation is used to change
the shape of metal workpieces
The tool, usually called a die, applies
stresses that exceed the yield strength of the
metal
The metal takes a shape determined by the
geometry of the die
Material Properties in Metal
Forming
Desirable material properties:
These properties are affected by temperature:
Low yield strength
High ductility
Ductility increases and yield strength decreases
when work temperature is raised
Other factors:
Strain rate and friction
Basic Types of Deformation
Processes
1.
Bulk deformation
Rolling
Forging
Extrusion
Wire and bar drawing
Sheet metalworking
2.
Bending
Deep drawing
Cutting
Miscellaneous processes
Bulk Deformation Processes
Characterized by significant deformations
and massive shape changes
"Bulk" refers to workparts with relatively low
surface areatovolume ratios
Starting work shapes include cylindrical
billets and rectangular bars
Rolling
Figure 18.2 Basic bulk deformation processes: (a) rolling
Forging
Figure 18.2 Basic bulk deformation processes: (b) forging
Extrusion
Figure 18.2 Basic bulk deformation processes: (c) extrusion
Wire and Bar Drawing
Figure 18.2 Basic bulk deformation processes: (d) drawing
Sheet Metalworking
Forming and related operations performed on
metal sheets, strips, and coils
High surface areatovolume ratio of starting
metal, which distinguishes these from bulk
deformation
Often called pressworking because presses
perform these operations
Parts are called stampings
Usual tooling: punch and die
Sheet Metal Bending
Figure 18.3 Basic sheet metalworking operations: (a) bending
Deep Drawing
Figure 18.3 Basic sheet metalworking operations: (b) drawing
Shearing of Sheet Metal
Figure 18.3 Basic sheet metalworking operations: (c) shearing
Material Behavior in Metal
Forming
Plastic region of stress-strain curve is primary
interest because material is plastically
deformed
Plastic Deformation of
Polycrystalline Metals
When a polycrystalline metal with uniform equiaxed
grains is subjected to plastic deformation at room
temperature (cold working), the grains become
deformed and elongated.
During plastic deformation, the grain boundaries
remain intact and mass contribution is maintained.
Deformed metal has high strength as the
entanglement of dislocations with grain boundaries
Plastic Deformation of
Polycrystalline Metals
Recovery, Recrystallization and
Grain Growth
Plastic deformation can be reversed by heating the
metal to a specific temperature range for a period of
time called annealing.
Three events take place during the heating process:
1. Recovery
During recovery, which occurs at high temperature
range below recrystallization temperature of the
metal, the stresses in the highly deformed regions
are relieved.
Subgrain boundaries will begin to formed, called
polygonization.
Recovery, Recrystallization and
Grain Growth
2. Recrystallization
It is the process in which new equiaxed and strainfree grains are formed.
The recrystallization temperature is defined as the
temperature at which complete recrystallization
occurs within one hour.
Recrystallisation decrease dislocations lower the
strength and raise the ductility of the metal.
Fig 1.14 shows the effects of recovery,
recrystallization and grain growth on mechanical
properties and on the shape and size of grains.
Recovery, Recrystallization and
Grain Growth
The effects on recrystallization of temperature, time
and plastic deformation by cold working are as
follow:
For a constant amount of deformation by cold
working, the time required for recrystallization to
occur decreases with increasing temperature.
The more the prior cold work, the lower the
temperature required for recrystallization.
The greater the degree of deformation, the smaller
the grain size becomes during recrystallization.
Anisotropy due to preferred orientation usually
persists after recrystallization .
Recovery, Recrystallization and
Grain Growth
3. Grain Growth
When increase temperature of metal
continuously, the grains will grow and their
size may eventually exceed the original grain
size and affects mechanical properties.
Temperature in Metal
Forming
Any deformation operation can be
accomplished with lower forces and power at
elevated temperature
Three temperature ranges in metal forming:
Cold working
Warm working
Hot working
Cold Working
Performed at room temperature or slightly
above
Many cold forming processes are important
mass production operations
Minimum or no machining usually required
These operations are near net shape or net
shape processes
Advantages of Cold Forming
Better accuracy, closer tolerances
Better surface finish
Strain hardening increases strength and
hardness
Grain flow during deformation can cause
desirable directional properties in product
No heating of work required
Disadvantages of Cold
Forming
Higher forces and power required in the
deformation operation
Surfaces of starting workpiece must be free
of scale and dirt
Ductility and strain hardening limit the
amount of forming that can be done
In some cases, metal must be annealed to
allow further deformation
In other cases, metal is simply not ductile
enough to be cold worked
Warm Working
Performed at temperatures above room
temperature but below recrystallization
temperature
Advantages of Warm Working
Lower forces and power than in cold working
More intricate work geometries possible
Need for annealing may be reduced or
eliminated
Hot Working
Deformation at temperatures above the
recrystallization temperature
Recrystallization temperature = about
onehalf of melting point on absolute scale
In practice, hot working usually performed
somewhat above 0.5Tm
Metal continues to soften as temperature
increases above 0.5Tm, enhancing advantage
of hot working above this level
Why Hot Working?
Capability for substantial plastic deformation of
the metal far more than possible with cold
working or warm working
Why?
Strength coefficient (K) is substantially less
than at room temperature
Strain hardening exponent (n) is zero
(theoretically)
Ductility is significantly increased
Advantages of Hot Working
Workpart shape can be significantly altered
Lower forces and power required
Metals that usually fracture in cold working can be
hot formed
Strength properties of product are generally
isotropic
No strengthening of part occurs from work
hardening
Advantageous in cases when part is to be
subsequently processed by cold forming
Disadvantages of Hot
Working
Lower dimensional accuracy
Higher total energy required (due to the
thermal energy to heat the workpiece)
Work surface oxidation (scale), poorer
surface finish
Shorter tool life
Friction in Metal Forming
In most metal forming processes, friction is
undesirable:
Metal flow is retarded
Forces and power are increased
Tooling wears faster
Friction and tool wear are more severe in hot
working
Lubrication in Metal Forming
Metalworking lubricants are applied to
toolwork interface in many forming
operations to reduce harmful effects of
friction
Benefits:
Reduced sticking, forces, power, tool wear
Better surface finish
Removes heat from the tooling
Considerations in Choosing a
Lubricant
Type of forming process (rolling, forging,
sheet metal drawing, etc.)
Hot working or cold working
Work material
Chemical reactivity with tool and work metals
Ease of application
Cost
Selecting Manufacturing
Process
Proper selection on suitable manufacturing process
between metal forming, machining & casting
process are based on
a) volume of production
b) quality & properties of product expected
e.g. surface finish, accuracy, etc.
c) technical viability (practicality of the process)
d) economy (cost & time)
END OF PART A
