PART[2] OF THE COURSE

FUNDAMENTALS OF
METAL FORMING

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Principles Of Metal Forming
Rolling
Extrusion
Deep drawing
Wire drawing
Others

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 Introduction
Practically all metals, which are not used in cast form
are reduced to some standard shapes for
subsequent processing.
 Manufacturing companies producing metals,
supply metals in form of ingots which are obtained by
casting liquid metal into a square cross section.

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 Definition of Metal Forming

Metal forming is a large

group of manufacturing
processes in which plastic
deformation is used to
change the shape of metal
workpiece.

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 Metal Forming
Processes

Bulk deformation Sheet metal working

Rolling Bending

Forging Deep drawing

Extrusion Shearing

Wire drawing
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Bulk Deformation Processes
 Characterized by significant deformations and
massive shape changes.
 "Bulk" refers to workparts with relatively low
surface area-to-volume ratios.
 Starting work shapes include cylindrical
billets and rectangular bars.

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 Sheet Metalworking
 Forming and related operations performed
on metal sheets, strips, and coils
 High surface area-to-volume ratio of starting
metal, which distinguishes these from bulk
deformation
 Often called pressworking because presses
perform these operations

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 Sheet metalworking operations:
Bending - Deep drawing

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Basic Bulk Deformation Processes

Rolling
Forging

Extrusion Wire drawing

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 ROLLING
 It is a compressive
deformation process in
which the thickness of a
slab or plate is reduced by
two opposing cylindrical
tools called rolls.

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 FORGING

 It is a deformation process
in which the W/P is
compressed between 2
opposing dies, so that the
die shapes are imparted to
the work.

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 EXTRUSION

 It is a compression process in
which the work metal is forced
to flow through a die opening

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 WIRE DRAWING

 It is a deformation process in
which the diameter of a wire or
bar is reduced by pulling it
through a die opening.
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Material Behavior in Metal Forming

σ= KЄ n

K – Strength coefficient [N/mm ] 2

n – Strain hardening exponent

σ – Stress
Є - Strain
•This curve is called the Flow curve.
•The stress and strain in the flow curve are true.
•The shown relationship is valid for cold working

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 FLOW STRESS
 Is the instantaneous value of stress required
to continue deforming the material, by other
words to keep the metal flowing. It is the
yield strength of the metal as a function of
strain,
Yf = KЄn
Where, Yf – Flow stress (MPa)

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AVERAGE FLOW STRESS (mean flow stress)
 It is the average value of stress over the
stress-strain curve from the beginning of
strain to the final or maximum value during
deformation.
 The average flow stress is determined by
integrating the flow curve equation from zero
to final value of strain.

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Location of Average Flow
on Stress - Strain Curve

K n
Yf 
1 n

Strain Rate

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 What is Strain Rate?
 Strain rate in forming is directly related to
speed of deformation v
 Deformation speed v = velocity of the ram or
other movement of the equipment
Strain rate is defined:
.v

.
h
where  = true strain rate; and h = instantaneous
height of workpiece being deformed

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Temperature in Metal Forming

 The flow curve is valid of metal during plastic

deformation, in case of cold working.
 The value of K and n depend on temperature.
 Strength and strain hardening are reduced at
higher temperatures.
 Ductility increases at higher temperatures.

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 COLD WORKING

These are the forming operations

that are performed at room
temperature or slightly above, it is
also called cold forming.

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Strain or Work Hardening
Strain hardening (work hardening) is where a
material becomes less ductile, harder and
stronger with plastic deformation.
 Encountered during cold working (CW%)

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Advantages and Limitations of Cold Working
Advantages Disadvantages
1. Better accuracy 1. Higher forces and
power required
2. Better surface finish 2. Starting w/p should
be free of scales.
3. Strain hardening leads 3. Limited deformation
to increase strength due to strain
and hardness. hardening
4. Directional properties
can be obtained
5. No heat required
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 Warm Working
 It is the deformation of a part at temperature above
room temperature but below the recrstallization
temperature, at 0.3Tm, where Tm is the melting
temperature.
 Advantages:
1. Lower forces and power comparing with cold working.
2. More possibility for geometries.
3. No need for annealing

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 HOT WORKING
 It is the deformation of a part at
temperature above the recrstallization
temperature, at 0.5Tm - 0.75Tm, where Tm is
the melting temperature.
 Advantages:
1. Produce substantial deformation far more
than cold working or warm working.
 Disadvantages:
1. Scales formation,
2. Increasing work temp. in localized region.

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 ISOTHERMAL FORMING
 It is the forming operations that are carried out in
such a way to eliminate surface cooling and the
resulting thermal gradient in the work part.

 Strain rate (380-382)

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 Bulk Deformation Processes

It is the deformation in which the work

is deformed by stressing the metal
sufficiently to cause it to plastically
flow into the desired shape.

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What does bulk deformation do?

1. Refine the raw shape,

2. Adding geometric features,

3. Improving mechanical properties,

4. Adding commercial value.

Friction & lubrication in metal forming (self study)

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