Metal Forming Related terms: Metal-forming offers some attractive characteristics that are superior to those Alloys, Metal Forming of other processes, for example, machining and chemical-etching, considering Process, Machining, _ such features as higher production rates, better material integrity, less waste, Forging, Friction, Oxide, Extrusion, Lubricant, lower manufacturing costs, etc. Lubricant, Microstructure, Texture From: Micromanufacturing Engineering and Technology (Second Edition), 2015 View all Topics > wt, Download as PDF J) Setalert © About this page Ultrasonic metal forming KF. Graff, in Power Ultrasonics, 2015 Abstract Metal forming is a primary manufacturing process that includes drawing, forging, rolling, and bending. Ultrasonic metal forming is the application of ultrasonic vibrations to these processes to enhance performance through increased production speeds, less tool wear, reduced forming forces, and better surface finish. The field was initiated with a 1955 rote by Blaha and Langenecker that reported reduced yield stress with application of ultrasound, resulting in lines of development active to the present day. Ultrasonic forming depends on the effects of vibrations on both the volume and surface of the metal being formed. This chapter reviews these effects on microstructure, macroscopic behavior, and surface friction. Ultrasonic metal forming KF, Graff, in Power Ultrasonics, 2015, Abstract Metal forming is a primary manufacturing process that includes drawing, forging, rolling, and bending. Ultrasonic metal forming is the application of ultrasonic vibrations to these processes to enhance performance through increased production speeds, less tool wear, reduced forming forces, and better surface finish. The field was initiated with a 1955 note by Blaha and Langenecker that reported reduced yield stress with application of ultrasound, resulting in lines of development active to the present day. Many metal forming processes have been investigated for application of power ultrasonics, including wire and tube drawing, deep drawing, bending, forging, and rolling. These and other processes, including shearing, surface treatment, microforming, and compaction are reviewed.Metal Forming: Microparts F. Vollertsen, in Encyclopedia of Materials: Science and Technology, 2001 6 Concluding Remarks In the metal forming of microparts, ie., parts with at least two dimensions below 1 mm, size effects of first and second order occur. These effects must be accounted for in the process layout. The effects on the mechanical strength and the tribological behavior have been already investigated, and essentials are settled. There is still a lack of research on the adhesion effects. It is possible to produce microparts using the metal forming technology. This is even true for gears which are very difficult to produce by metal forming in the normal size range. Conclusions Maziar Ramezani, Zaidi M. Ripin, in Rubber-Pad Forming Processes, 2012 Different metal forming operations such as bending, drawing, embossing, blanking, piercing, and bulging are performed Using flexible tools and the details of the processes and their results are shown throughout the book. Due to the more Uniform exertion of applying pressure to the workpiece by using elastic tools, parts with more uniform wall thickness and less springback and wrinkle can be generated. Deeper cups can be produced by friction-assisted deep drawing processes as the beneficial friction delays the onset of wrinkling and fracture. Furthermore, the friction between the rubber pad and the metallic parts can be used as blankholding force. This technique greatly simplifies the tooling set-up and a single action press without a cushion can be used for deep drawing processes. The friction-assisted metal forming techniques can also be used for collar drawing and redrawing of cups. Machining and Nonmechanical Shaping: A Comparison G. Spur, F. Elbing, in Encyclopedia of Materials: Science and Technology, 2001 2 Metal Forming Processes Metal forming is the direct alteration of form, surface, and material properties of a workpiece while preserving mass and cohesion. The processes of forming use the plasticity of metals for the production of semifinished material and structural parts. Forming is based on the flexible moldability of numerous materials and relies on the ability of the material structure to bear unit deformations along crystalline gliding planes without damaging the material cohesion. Forming saves material as no waste is produced. The objective is to obtain a finished surface in order to avoid expensive finishing. Metal forming processes are classified according to the effective stresses into forming under (i) compressive, (ji) 2 combination of tensile and compressive, (ii) tensile, (iv) bending, and (¥) shearing conditions. Important processes are upsetting, wire drawing, deep drawing, extruding, stretch forming, bending, and forging. The forming process is influenced by the workpiece, the tool, the lubricant, the environment medium, and the machine. It can be described by means of yield stress, deformation size, low conditions, anisotropy, and the flow curve. Processing heated workpieces is called hot forming, while processing workpieces at ambient temperature is called cold forming. With metallic materials cold forming is usually accompanied by work hardening, which is characterized by the fact that with increasingwororniauuiy pions atLerU! anu Urcanin SucHgit HRCESE ate Ucaniig crUNaNON UcuiEaseD. The description of forming processes is based on three basic models, the homogeneous shaping of disks, strips, and tubes. The basis is a homogeneous, isotropic material with a constant friction between workpiece and tool, and a constant yield stress. The strip model forming process is described briefly. A strip of a minimum breadth between two parallel delimitation surfaces between the upper and lower forming tool is considered. The upper and lower barrier is regarded as tangential to the contour of the tool. The strip height and the angles described depend on the moving sense of the tool. It is assumed that neighboring cross-sectional areas of the strip remain even and parallel to each other. Only compression stresses are considered, which normally affect the cross-section and delimitation surfaces, the remaining loads are neglected. By multiplying the tensions with the appropriate surfaces the forces affecting these surfaces are obtained. These forces are divided into horizontal and vertical forces and describe the loads at the delimitation surfaces ofthe strip. Assessing Properties of Conventional and Specialized Materials “TB. Stoughton, .W. Yoon, in Comprehensive Materials Processing, 2014 Abstract ‘The metal-forming industry routinely uses forming limit criteria in the analysis of stamped sheet metal and tube hydroformed components to obtain more robust manufacturing processes and improved product performance characteristics. These criteria are essential to computer-aided engineering during product design and manufacturing process development for analysis of the predicted stress and strain histories of the deformation process. Forming limit criteria are also helpful later during physical validation of the sheet-forming process, and during die tryout for analysis of measurements of actual forming strains and strain histories, to help ensure robust manufacturing in production. Finally, forming limit criteria are an essential element of computer-aided engineering of product design to help optimize performance requirements early in the product development cycle and reduce the dependence on physical testing to achieve optimal product performance. INTRODUCTION Amir R. Khoei, in Computational Plasticity in Powder Forming Processes, 2005 1.2 Design of forming process In metal forming, an initially simple partis plastically deformed between tools or dies to obtain the desired final configuration. Thus, a simple part geometry is transformed into a complex one, in a process whereby the tools store the desired geometry and impart pressure on the deforming material through the tool-material interface. The physical phenomena constituting a forming operation are difficult to express with quantitative relationships. The metal flow, the friction at the tool-material interface, the heat generation and transfer during plastic flow, and the relationships between microstructure/properties and process conditions are difficult to predict and analyze. Often, in producing discrete parts, several forming operations are required to transform the initial ‘simple’ geometry into a ‘complex’ geometry, without causing material failure or degrading material properties. Consequently, the most significant objective of any method of analysis is to assist the forming engineer in the design of forming and/or performing sequences. For a given operation (performing or finish-forming), such design essentially consists of