METAL FORMING PROCESS Plastic Deformation Processes Operations that induce shape changes on the workpiece by plastic deformation

under forces applied by various tools and dies. Bulk Deformation Processes These processes involve large amount of plastic deformation. The cross-section of workpiece changes without volume change. The ratio cross-section area/volume is small. For most operations, hot or warm working conditions are preferred although some operations are carried out at room temperature. Classification of Bulk Deformation Processes Rolling: Compressive deformation process in which the thickness of a plate is reduced by squeezing it through two rotating cylindrical rolls. Forging: The workpiece is compressed between two opposing dies so that the die shapes are imparted to the work. Extrusion: The work material is forced to flow through a die opening taking its shape Drawing: The diameter of a wire or bar is reduced by pulling it through a die opening (bar drawing) or a series of die openings (wire drawing)

Sheet-Forming Processes In sheet metalworking operations, the cross-section of workpiece does not changethe material is only subjected to shape changes. The ratio cross-section area/volume is very high. Sheet metalworking operations are performed on thin (less than 6 mm) sheets, strips or coils of metal by means of a set of tools called punch and die on machine tools called stamping presses. They are always performed as cold working operations. Classification of Sheet Metalworking Processes Shearing: It is a sheet metal cutting operation along a straight line between two cut-ting edges by means of a power shear. Blanking and punching: They are similar sheet metals cutting operations that involve cutting the sheet metal along a closed outline. If the part that is cut out is the desired product, the operation is called blanking and the product is called blank. If the remaining stock is the desired part, the operation is called punching. Bending: It is defined as the straining of the sheet metal around a straight edge Deep drawing: It is a sheet-metal operation to make hollow-shaped parts from a sheet blank

CASTING PROCESSES
Sand Casting The figure illustrates the basic production steps in sand casting:

Patterns Patterns in sand casting are used to form the mold cavity. One major requirement is that patterns (and therefore the mold cavity) must be oversized (i) (ii) to account for shrinkage in cooling and solidification, and to provide enough metal for the subsequence machining operation(s).

Cores Cores serve to produce internal surfaces in castings. In some cases they have to be supported by chaplets for more stable positioning:

Cores are made of foundry sand with addition of some resin for strength by means of core boxes:

Foundry sands The typical foundry sand is a mixture of fresh and recycled sand, which contains 90% silica (SiO2), 3% water, and 7% clay. The grain size and grain shape are very important as they define the surface quality of casting and the major mold parameters such as strength and permeability: