Deformation Processes: Hot working and cold working of metals, Forging processes, Open and

closed die forging process. Typical forging operations, Rolling of metals, Principle of rod and
wire drawing, Tube drawing. Principle of Extrusion, Types of Extrusion, Hot and Cold extrusion.

Sheet metal characteristics -Typical shearing operations, bending and drawing operations,
Stretch forming operations, Metal spinning.
 HOT WORKING and COLD WORKING
COLD WORKING is metal forming performed at room temperature.
Advantages: better accuracy, better surface finish, high strength and
hardness
Disadvantages: higher forces and power, additional annealing for some
material is required, and some material are not capable of cold
working.

WARM WORKING is metal forming at temperatures above the room

temperature but bellow the recrystallization one.

HOT WORKING involves deformation of material above the re

crystallization temp.
Avantages: big amount of forming is possible, lower forces and power
are required, forming of materials with low ductility, no work
hardening and therefore, no additional annealing is required.
Disadvantages: lower accuracy and surface finish, higher production
cost, and shorter tool life.
METAL TEMP. (degree Cel.)
ALUMINIUM 150
COPPER 200
IRON 450
NICKEL 590
ZINC At room temp
LEAD Below room temp
TIN Below room temp
 METAL FORMING PROCESS

COLD WORKING
HOT WORKING 1. COLD ROLLING
1.FORGING 2. COLD EXTRUSION
2.ROLLING 3. COLD FORGING
3.EXTRUSION 4. WIRE DRAWING
5. SHEET METAL
4.HOT DRAWING PROCESS
 FORGING

Forging: The workpiece is compressed between two opposing dies so that

the die shapes are imparted to the work.
Forging
Definition
Forging is a Bulk Deformation Process in which
the work is compressed between two dies.
According to the degree to which the flow of
the metal is constrained by the dies there are
three types of forging:

 Open-die forging
 Impression-die forging
 Flash less forging
Forging
GRAIN FLOW
 FORGING METHODS

1.SMITH FORGING
2.DROP FORGING
3.PRESS FORGING
4.MACHINE OR UPSET FORGING
SMITH OR HAND FORGING
SMITH OR HAND FORGING
TOOLS & TYPE OF SMITH FORGING

1. FULLERING
2. FLATTENING
3. SWAGING
4. PUNCHING
5. DRIFTING
6. BENDING
7. SETTING DOWN
FORGING TOOLS
FORGING TOOLS
FORGING TOOLS
FORGING TOOLS
FORGING TOOLS

COLD & HOT CHISEL

FORGING TOOLS
FORGING TOOLS
FORGING TOOLS
FULLERING
FULLERING
FLATTENING
SWAGING
PUNCHING
DRIFTING
BENDING
DROP FORGING
PRESS FORGING
UPSET OR MACHINE
FORGING
UPSET OR MACHINE FORGING
(CLOSE)
UPSET OR MACHINE
FORGING (OPEN)
 EXTRUSION

Extrusion: The work material is forced to flow through a die opening taking
its shape
 EXTRUSION
• In the extrusion process, metal is compressed and forced to flow through a suitably shaped die to form a
product with reduced but constant cross section.
• Extrusion may be performed either hot or cold,
• Extrusion process is like squeezing toothpaste out of a tube.
• Extruded products have good dimensional precision.

• Direct extrusion: A metal billet is

located into a container, and a ram
compresses the material, forcing it to
flow through one or more openings in
a die at the opposite end of the
container.

• Indirect extrusion: The die is mounted

to the ram rather than at the opposite
end of the container. One advantage
of the indirect extrusion process is
that there is no friction, during the
process, between the billet and the
container liner .
 ROLLING

Rolling: Compressive deformation process in which the thickness of a plate is

reduced by squeezing it through two rotating cylindrical rolls.
 Basic Rolling Process
• Heated metal is passed between two
rolls that rotate in opposite directions
• Gap between rolls is less than
thickness of entering metal.
• Rolls rotate with surface velocity that
exceeds speed of incoming metal,
friction along the contact interface acts
to propel the metal forward.
• Metal is squeezed and elongates result
in decrease of the cross-sectional area.
• Amount of deformation in a single pass
depends on the friction conditions
along the interface.
• If too much material flow is demanded,
rolls cannot advance the material and
simply skid over its surface.

FORGING DEFECTS ?
 HOT DRAWING

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)
DRAWING
Drawing is an operation in which the cross-section of solid rod, wire or tubing is reduced or
changed in shape by pulling it through a die.

The principle of this procedure consist of reducing the thickness of a pointed ,tapered wire by
drawing it through a conical opening in a tool made of a hard material.The wire will take shape of
the hole.

Drawing improves strength and hardness when these properties are to be developed by cold work
and not by subsequent heat treatment.

This process is widely used for the production of thicker walled seamless tubes and cylinders
therefore; shafts, spindles, and small pistons and as the raw material for fasteners such as rivets,
bolts, screws.
Swaging
• Swaging generally involves the hammering of a rod or tube to reduce its diameter where the die
itself acts as the hammer
• Term swaging is also applied to processes where material is forced into a confining die to
reduce its diameter.
Swaging with and without a Mandrel
(a) Swaging of tubes without a mandrel; note the increase in wall thickness in the die gap. (b) Swaging with a
mandrel; note that the final wall thickness of the tube depends on the mandrel diameter. (c) Examples of cross-
sections of tubes produced by swaging on shaped mandrels. Rifling (internal spiral grooves) in small gun barrels
can be made by this process.
 SHEET METAL WORKING: USE
Many useful durable goods like: Cars, Equipment, Cabinetry, Duct Work, Toys, etc.
Typical products made by sheet metal working: Utensils, Furniture, Body of vehicle etc.

Sheet metal parts for consumer and industrial products such as: Automobiles and trucks,
Airplanes, Railway cars and locomotives, Farm and construction equipment, Small and large appliances, Office
furniture , Computers and office equipment

Advantages of Sheet Metal Parts

Good dimensional accuracy, Good surface finish, Relatively low cost
For large quantities, economical mass production operations are available
What is Sheet Metal?
• Metal that has been rolled into a sheet having a thickness between foil and plate.
– greater than 1/64 inch and no larger than 1/4 inch
• Anything thinner is referred to as a foil and thicker is considered as a plate.
• Sheet thickness is generally measured in gauge. Greater the gauge number, thinner
the sheet of metal.
• Sheet metal can be cut, bent and stretched into nearly any shape.
Cutting and forming operations performed on relatively thin sheets of metal
• Thickness of sheet metal = 0.4 mm (1/64 in) to 6 mm (1/4 in)
• Thickness of plate stock > 6 mm
• Operations usually performed as cold working
 Metals used for sheets
There are many different metals that can be made
into sheet metal, such as
aluminum, brass, copper, steel, tin, nickel & titanium

For decorative uses, important sheet metals

include silver, gold, and platinum.

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 Steel (American Wire Gauge in inch)
Gauge Thickness
28 0.015”
26 0.018”
24 0.024”
22 0.030”
20 0.036”
18 0.048”
16 0.060”
14 0.075”
12 0.105
11 0.120”
10 0.134”
8 0.160”
7 0.1874”

standard specification for sheets,

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 Bending  perforating
 Shearing  Nibbling
 Blanking  Embossing
 Punching  Shaving
 Trimming  Cutoff
 Parting  dinking
 Slitting  Coining
 Lancing  Deep drawing
 Notching  Stretch forming
 Roll forming
 Three Major Categories of
Sheet Metal Processes
1. Cutting
◦ Shearing to separate large sheets; or cut
part perimeters or make holes in sheets

2. Bending
◦ Straining sheet around a straight axis

3. Drawing
◦ Forming of sheet into convex or concave
shapes

46
I. Cutting
Three principal operations in pressworking that cut sheet metal:
Shearing
Blanking
Punching

Shearing between two sharp cutting edges

47
 Shearing is defined as separating material into two parts.
 It utilizes shearing force to cut sheet metal.

Sheet metal cutting operation along a straight line between two cutting
edges
Typically used to cut large sheets into smaller sections for subsequent
operations
 Blanking and Punching
Blanking - sheet metal cutting to separate piece from
surrounding stock
• Cut piece is the desired part, called a blank

Punching - sheet metal cutting similar to blanking except cut

piece is scrap, called a slug
• Remaining stock is the desired part

(a) Blanking and (b) punching 49

The typical punching operation, in which a cylindrical punch
pierces a hole into the sheet.
 A piece of sheet
metal is removed
from a larger piece
of stock.
 This removed piece

is not scrap, it is
the useful part.
NOTCHING
Punching the edge of a sheet, forming a notch in the shape of a portion of the punch.

Notch created
Sheet by cutting a piece
fromthe edge
Perforating: Punching a close arrangement of a large number of holes in a single operation.

Equispaced holes
LANCING:
Creating a partial cut in the sheet, so that no material is removed. The material is left attached
to be bent and form a shape, such as a tab, vent, or louver.

Sheet

Sheet cut and

bent
 Punching a series
of small
overlapping slits or
holes along a path
to cut-out a larger
contoured shape.
 Punching away
excess material
from the perimeter
of a part, such as
trimming the
flange from a
drawn cup.
 Separating a
part from the
remaining
sheet, by
punching away
the material
between parts.
Cutting straight lines in the sheet. No scrap
material is produced.
Shearing away minimal
material from the edges of a
feature or part, using a small
die clearance. Used to
improve accuracy or finish.
Tolerances of
±0.025 mm are
possible.
 BEADING

FLANGING

(a) Sheet to be flanged (b) Flanged sheet

HEMMING

SEAMING

(a) Sheets to be joined (b) Joint made by seaming

 EMBOSSING
 Used to create indentations in sheet, such as raised (or indented) lettering or strengthening ribs.
• Certain designs are embossed on the sheet metal.
•  Punch and die are of the same contour but in opposite direction

Embossing: (a) cross-section of punch and die

configuration during pressing; (b) finished part with
embossed ribs

Workpiece

Embossed Female die with Male die with

letter E depressions projections
COINING
Similar to embossing with the difference that similar or different impressions are obtained on both the sides
of the sheet metal.

Punch
C oin

G uide

D ie
1. Bending
Straining sheetmetal around a straight axis to take a permanent bend.
Bending is a metal forming process in which a force is applied to a piece of sheet metal, causing it
to bend at an angle and form the desired shape.

(b) both compression and tensile

elongation of the metal occur in
bending
(a) Bending of sheet metal
 Types of Sheetmetal Bending
V-bending - performed with a V-shaped die
Edge bending - performed with a wiping die

V-Bending Edge Bending

• For low production • For high production
• Performed on a press brake • Pressure pad required
• V-dies are simple and
• Dies are more
inexpensive
complicated and costly
Straight flanging Stretch flanging Shrink flanging

Hemming Seaming Curling

 Springback in Bending
Springback = increase in included angle of bent part
relative to included angle of forming tool after tool is
removed
• Reason for springback:
– When bending pressure is removed, elastic energy remains
in bent part, causing it to recover partially toward its
original shape

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2. Drawing
Sheet metal forming to make cup-shaped, box-shaped, or
other complex-curved, hollow-shaped parts
Products: beverage cans, ammunition shells, automobile body panels

c = Clearance
Db = blank diameter
Dp = Punch diameter
Rd = die corner radius
Rp = Punch corner
radius
F = drawing force
Fh = holding force
DEEP DRAWING

 Deep drawing is a metal forming process in which sheet metal is stretched into the desired shape.
 A tool pushes downward on the sheet metal, forcing it into a die cavity in the shape of the desired part.

Common applications: cooking pots, containers, …

Deep Drawing

Initial step bending of edge straightening of side wall

Thinning and drawing final cup shape

3. Stretch Forming
Sheet metal is stretched and simultaneously bent to achieve
shape change

Stretch forming is a metal forming process in which a piece of

sheet metal is stretched and bent simultaneously over a die
in order to form large bent parts

Stretching and forming with a die at the same time.

Stretch forming: (1) start of process; (2) form die is pressed into the work
with force Fdie, causing it to be stretched and bent over the form. F =
stretching force
4. Spinning
Metal forming process in which an axially symmetric part is gradually
shaped over a rotating mandrel using a rounded tool or roller

Conventional spinning: (1) setup at start of process; (2) during spinning;

and (3) completion of process