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Manufacturing Processes II: Fundamentals of Metal Forming

The document discusses various metal forming processes including machining, forming, and deformation techniques like hot, cold, and warm working. It covers key variables that influence forming like temperature, lubrication, and friction. Forming methods are selected based on their advantages and limitations regarding factors like required force, achievable precision and finishes, and impact on material properties.

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Mohamed Galal Mekawy
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© © All Rights Reserved
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29 views

Manufacturing Processes II: Fundamentals of Metal Forming

The document discusses various metal forming processes including machining, forming, and deformation techniques like hot, cold, and warm working. It covers key variables that influence forming like temperature, lubrication, and friction. Forming methods are selected based on their advantages and limitations regarding factors like required force, achievable precision and finishes, and impact on material properties.

Uploaded by

Mohamed Galal Mekawy
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Manufacturing Processes II

ISE 304N

Fundamentals of Metal Forming


Introduction

• Deformation processes have been designed


to exploit the plasticity of engineering
materials
• Plasticity is the ability of a material to flow as
a solid without deterioration of properties
• Deformation processes require a large
amount of force
Machining
• Processes include bulk flow, simple shearing
or compound bending • Turning
• Drilling
• Milling
• Grinding

Chapters 21, 22, 23, 24


Forming Operations

Machining
• Turning
• Drilling
• Milling
• Grinding

Chapters 21, 22, 23, 24


Forming Processes

https://www.youtube.com/watch?v=CfDpITBfPx0

https://www.youtube.com/watch?v=08gf_uhunxA
Forming Processes: Variables

Independent Variables Links Dependent Variables


• Starting material • Force or power
• Starting geometry of the wok-piece o Experience requirements
• Tool or die geometry • Material properties of the
• Lubrication o Experiment product
• Starting temperature • Exit or final temperature
• Speed of operation o Modeling • Surface finish and precision
• Amount of deformation • Nature of the material flow
General Parameters
• Material deformed must be characterized
o Strength or resistance for deformation
o Conditions at different temperatures
o Formability limits
o Reaction to lubricants

• Speed of deformation and its effect

• Speed-sensitive materials – more energy is


required to produce the same results
Friction and Lubrication Under Metalworking Conditions
• High forces and pressures are required to
deform material

• For some processes, 50% of the energy spent in


overcoming friction

• Changes in lubrication can alter material flow,


create or eliminate defects, alter surface finish
and dimensional precision, and modify product
properties

• Production rates, tool design, tool wear, and


processes optimization depend on the ability to
determine and control friction
Friction and Lubrication Under Metalworking Conditions
Lubrication
• Key to success in many metal-forming operations
• Primarily selected to reduce friction and tool wear,
but may be used as a thermal barrier, coolant, or
corrosion retardant
Friction • Other factors
Ease of removal, lack of toxicity, odor,
• Friction is resistance to sliding along an
flammability, reactivity, temperature, velocity,
interface wetting characteristics
• Resistance can be attributed to:
o Abrasion Surface Deterioration
o Adhesion • Surface wear is related to friction
• Resistance is proportional to the strength of • Wear on the work-piece is not
the weaker material and the contact area objectionable, but wear on the tooling is
• Tooling wear is economically costly and
can impact dimensional precision
• Tolerance control can be lost
• Tool wear can impact the surface finish
Temperature Concerns
• Work-piece temperature can be one of the
most important process variables

• In general, an increase in temperature is


related to a decrease in strength, increase in
ductility, and decrease in the rate of strain
hardening

• Hot working > 0.6 melting point


• Cold working < 0.3 melting point
• Warm working 0.3 ~ 0.6 melting point
Hot Working
• Plastic deformation of metals at a temperature
above the recrystallization temperature

• Temperature varies greatly with material

• Recrystallization removes the effects of strain


hardening

• Hot working may produce undesirable reactions


from the metal and its surroundings
Hot Working
• The size of grains upon cooling is not typically
uniform

• Undesirable grain shapes can be common (such


as columnar grains)

• Recrystallization is followed by:


o Grain growth
o Additional deformation and recrystallization
o Drop in temperature that will terminate
diffusion and freeze the recrystallized
structure
Hot Working
• Engineering properties can be improved through reorienting inclusion or impurities

• During plastic deformation, impurities tend to flow along with the base metal or
fraction into rows of fragments
Hot Working
• Engineering properties can be improved through
reorienting inclusion or impurities
• During plastic deformation, impurities tend to flow
along with the base metal or fraction into rows of
fragments
• Success or failure of a hot deformation process often
depends on the ability to control temperatures
• Over 90% of the energy imparted to a deforming work-
piece is converted to heat
• Non-uniform temperatures may be produced and may
result in cracking
• Thin sections cool faster than thick sections
Cold Working
Plastic deformation below the recrystallization temperature

Advantages Disadvantages
• No heating required • Higher forces are required to initiate and
• Better surface finish complete the deformation
• Superior dimensional control • Heavier and more powerful equipment and
• Better reproducibility stronger tooling are required
• Strength, fatigue, and wear are improved • Less ductility is available
• Directional properties can be imparted • Metal surfaces must be clean and scale-free
• Contamination is minimized • Intermediate anneals may be required
• Imparted directional properties can be
detrimental
• Undesirable residual stresses may be
produced
Cold Working
• Two features that are significant in selecting a
material for cold working are:
• Magnitude of the yield-point stress
• Extent of the strain region from yield stress
to fracture

• Spring-back should also be considered when


selecting a material

• Quality of the starting material is important to


the success or failure of the cold-working process

• The starting material should be clean and free of


oxide or scale that might cause abrasion to the
dies or rolls
Warm Forming
Deformations produced at temperatures intermediate to
cold and hot working

Advantages

• Reduced loads on the tooling and


equipment
• Increased material ductility
• Possible reduction in the number of anneals
• Less scaling and decarburization
• Better dimensional precision and smoother
surfaces than hot working
• Used for processes such as forging and
extrusion
Isothermal Forming
• Deformation that occurs under constant
temperature

• Dies and tooling are heated to the same


temperature as the work-piece

• Eliminates cracking from non-uniform


surface temperatures

• Inert atmospheres may be used

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