4

Metal Shaping and Forming

Course Contents
4.1 Introduction
4.2 Plastic Deformation
4.3 Work Hardening
4.4 Hot Working
4.5 Cold Working
4.6 Metal Forming
4.7 Bulk Deformation Processes
4.8 Hot Rolling
4.9 Roll Piercing or Seamless Tubing
4.10 Cold rolling
4.11 Forging
4.12 Types of Forging process
4.13 Open Die Forging
4.14 Impression Die or Closed Die Forging
4.15 Hammers and other Forging Tools
4.16 Drop forging
4.17 Forging Operations
4.18 Extrusion
4.19 Defects in Extrusion
4.20 Wire Drawing
4.21 Tube Drawing
4. Metal Shaping and Forming Manufacturing process-II (2141908)

4.1 Introduction
− Mechanical working of a metal is a simply plastic deformation performed to change the
dimensions, properties and surface conditions with the help of mechanical pressure.
− Depending upon the temperature and strain rate, mechanical working may be either hot
working or cold working, such that recovery process takes place simultaneously with the
deformation.
− The plastic deformation of metal takes place due to two factors i.e. deformation by slip
and deformation by twin formation.
− During deformation the metal is said to flow, which is called as plastic flow of the metal
and grain shapes are changed.
− If the deformation is carried out at higher temperatures, then the new grains start
growing at the locations of internal stresses.
− When the temperature is sufficiently high, the grain growth is accelerated and continue
still the metal comprises fully of new grains only.
− This process of formation of new grains is called as recrystallisation and the
corresponding temperature is the recrystallisation temperature of the metal.
− Recrystallisation temperature is the point which differentiates hot working and cold
working.
− Mechanical working of metals above the recrystallisation temperature, but below the
melting or burning point is known as hot working whereas; below the recrystallisation
temperature, is known as cold working.
4.2 Plastic Deformation
− Any external or internal forces cause stresses in the material resulting into deformation.
− Deformation is of two basic types :
o Elastic Deformation : Stress is below the elastic limit,
o Plastic Deformation: Stress is above the elastic limit.
− When the body regains its original shape on the removal of externally applied force the
deformation is called as elastic deformation.
− Elastic deformation occurs upto the maximum value of stress upto which the
deformations are elastic or temporary.
− Stress required during elastic deformation is lower than plastic deformation.
− The plastic deformation is an important property of metals and non-metals, due to
which materials can be deformed permanently and shaped as per the requirement.
− Plastic deformation can be done through forming, rolling, drawing, forging, etc.
− Plastic deformation may occur by :
o Slip or
o Twinning or
o Both acting simultaneously

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− Plastic deformation is permanent and takes place when the applied stress level exceeds
a certain limit known as yield stress. Refer Fig. 4.1.

Fig. 4.1: Ideal plastic deformation preceded by ideal elastic deformation

4.3 Work Hardening
− It is the phenomenon by which metals become harder and stronger during mechanical
working or straining i.e. during plastic deformation of the metal.
− After initial work hardening or straining, more and more stress is required to further
deform the material.
− E.g. During the operation of hammering a nail, quite often the nail bends. This bending
of nail induces stress development inside the nail.
− The nail gets plastically deformed and work hardened or strained.
− Now if we try to straighten the nail, it requires more force than that required to bend it.
− Work hardening or Straining occurs below the re-crystallization temperature.
4.4 Hot Working
− Hot working is accomplished at a temperature above the recrystallisation temperature
but below the melting or the burning point of the metal, because above the melting or
the burning point, the metal will burn and become unsuitable for use.
− Every metal has a characteristic hot working temperature range over which hot working
may be performed.
− The upper limit of working temperature depends on composition of metal, prior
deformation and impurities within the metal.
− The changes in structure from hot working improves mechanical properties such as
ductility, toughness, resistance to shock and vibration, % elongation, % reduction in
area, etc.
− The principal hot working processes applied to various metals are as follows :
1. Hot rolling 3. Hot spinning 5. Hot drawing
2. Hot extrusion 4. Roll piercing 6. Hot forging
Advantages:
− Due to hot working, no residual stresses are introduced in the metal.
− Hot working refines grain structure and improves physical properties of the metal.

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− Any impurities in the metal are disintegrated and distributed throughout the metal.
− Porosity of the metal is minimised by the hot working.
− During hot working, as the metal is in plastic state, larger deformation can be
accomplished and more rapidly.
− Hot working produces raw material which is to be used for subsequent cold working
operations.
Disadvantages:
− As hot working is carried out at high temperatures, a rapid oxidation or scale formation
takes place on the metal surface which leads to poor surface finish and loss of metal.
− Due to the loss of carbon from the surface of the steel piece being worked, the surface
layer loses its strength.
− This weakening of the surface layer may give rise to fatigue crack which results in failure
of the part.
− Close tolerances cannot be obtained.
− Hot working involves excessive expenditure on account of high tooling cost.
4.5 Cold Working
− The working of metals at temperatures below their recrystallisation temperature is
called as cold working.
− Most of the cold working processes are performed at room temperature.
− Unlike hot working, it distorts the grain structure and does not provide an appreciable
reduction in size.
− Cold working requires much higher pressure than hot working.
− If the material is more ductile, it can be more cold worked.
− Residual stresses are setup during the process, hence to neutralize these stresses a
suitable heat treatment is required.

Fig. 4.2: Effects on properties of material due to Cold Working

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− The principal methods of cold working are as follows :

1. Cold rolling 2. Cold drawing 3. Cold spinning
4. Stretch forming 5. Cold forging and swaging 6. Cold extrusion
7. Coining 8. Embossing 9. Cold bending
10. Roll forming 11. Shot peening 12. High Energy Rate
Forming (HERF)
− Cold Working results in Strain Hardening, distortion of grains and the crystallographic
structure.
− Various mechanical properties are dependent on the crystallographic structure.
− Refer Fig. 4.2 showing the various effects on properties of material due to cold working
operation.
− Cold working of metals have following advantages and disadvantages :
Advantages:
− Better dimensional control is possible because there is not much reduction in size.
− Surface finish of the component is better because no oxidation takes place during the
process.
− Strength (tensile strength and yield strength) and hardness of metal are increased.
− It is an ideal method for increasing hardness of those metals which do not respond to
the heat treatment.
Disadvantages:
− Ductility of the metal is decreased during the process.
− Only ductile metals can be shaped through the cold working.
− Over-working of metal results in brittleness and it has to be annealed to remove this
brittleness.
− To remove the residual stresses setup during the process, subsequent heat treatment is
mostly required.
4.5.1 Comparison between Hot Working and Cold Working
Sr.
Hot working Cold working
No.
Hot working is carried out above the Cold working is carried out below the
recrystallisation temperature but below recrystallisation temperature and as such
1. the melting point, hence deformation there is not appreciable recovery of
of metal and recovery takes place metal.
simultaneously.
During the process, residual stresses During the process, residual stresses are
2.
are not developed in the metal. developed in the metal.
Because of higher deformation The stress required to cause deformation
3. temperature used, the stress required is much higher.
for deformation is less.
4. Hot working refines metal grains, Cold working leads to distortion of grains.

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4. Metal Shaping and Forming Manufacturing process-II (2141908)

resulting in improved mechanical

properties.
5. No hardening of metal takes place. Metal gets work hardened.
If the process is properly performed, it It improves ultimate tensile strength,
does not affect ultimate tensile yield and fatigue strength but reduces
6.
strength, hardness, corrosion and corrosion resistance of the metal.
fatigue resistance of the metal.
It also improves some mechanical During the process, impact strength and
7. properties like impact strength and elongation are reduced.
elongation
Due to oxidation and scaling, poor Cold worked parts carry better surface
8.
surface finish is obtained. finish.
Close dimensional tolerances cannot be Superior dimensional accuracy can be
9.
maintained. obtained.
Hot working is most preferred where Cold working is preferred where work
10.
heavy deformation is required. hardening is required.
4.6 Metal Forming
− Metal forming includes a large number of manufacturing processes in which plastic
deformation property is used to change the shape and size of metal work pieces.
− During the process, for deformation purpose, a tool is used which is called as die. It
applies stresses to the material to exceed the yield strength of the metal.
− Due to this the metal deforms into the shape of the die. Generally, the stresses applied
to deform the metal plastically are compressive.
− But, in some forming processes metal stretches, bends or shear stresses are also applied
to the metal.

Fig. 4.3: Classification of metal forming processes

− For better forming of metal, the desirable properties of metal are low yield strength and
high ductility.

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− These properties are highly affected by the temperature. When the temperature of the
metal is increased, its ductility increases and yield strength decreases.
− The other factors which affect the performance of metal forming process are, strain
rate, friction, lubrication, etc.
− Metal forming processes can be classified as follows :
4.7 Bulk Deformation Processes
− Bulk deformation processes are performed as hot, cold or warm working processes.
− These processes are characterized by significant deformations and massive shape
changes but the surface area to the volume of the work is relatively small.
− The work pieces which have this low area to volume ratio is called as bulk.
− Initial work piece shapes for bulk deformation processes include cylindrical billet(hot
material) and rectangular bars.
− Fig. 4.4 shows the basic operations in bulk deformation process.

Fig. 4.4: Basic bulk deformation processes

1. Rolling
− It is a compressive deformation process in which the thickness of a plate or slab (hot) is
reduced by two opposing cylindrical rolls.
− The rolls rotate in order to draw the work piece into the gap between them and squeeze
the work piece. Refer Fig. 4.6 (a)
2. Forging
− In this process, the work piece is compressed between the two opposing dies in order to
produce the die shapes on the work piece. Refer Fig. 4.6 (b).

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4. Metal Shaping and Forming Manufacturing process-II (2141908)

− It is generally a hot working process but sometimes it can be included in cold working
also.
3. Extrusion
− It is a compressive deformation process in which the work metal is forced to flow
through a die opening as shown in Fig. 4.6 (c).
− During the flow through a die, the work metal takes the shape of the opening as its
cross-section.
4. Wire drawing
− In this type of forming process, the diameter of a round bar (billet) is reduced by pulling
it through a die opening.
− Fig. 4.6 (d) shows the drawing process.
4.7.1 Sheet Metal Working Processes
− Sheet metal working processes are usually performed as cold working process.
− In this type of metal forming processes, the operations are performed on metal sheets,
strips and coils.
− In these processes, the surface area to volume ratio is high.
− Generally, the sheet metal working processes are carried out on punching press
machine; hence sheet metal working is also called as press working.
− A component produced by sheet metal working process is called as stamping.
− These operations are performed as cold working processes. The tools used for the
operations are called as punch and die.
− The punch is a positive portion whereas the die is a negative portion of the tool set.
− Fig. 4.5 shows the basic operations in sheet metal working process.
− Bending

Fig. 4.5: Basic sheet metal working operations

− In this process, there is straining of metal sheet or plate to take an angle along a straight
axis. Refer Fig. 4.7 (a).
− The bending may be of V shape, U shape or any other shape.

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− Drawing or Cupping
− It refers to the forming of a flat metal sheet into a hollow or concave shape like a cup by
stretching the metal.
− During the process, a blank holder is used to hold the blank and the punch pushes into
the sheet metal. Refer Fig. 4.7 (b).
4.8 Hot Rolling
− The process of rolling consists of passing the hot ingot through the two rolls, rotating in
opposite directions, at a uniform peripheral speed.
− To confirm the desired thickness of the rolled section, the space between the rolls is
adjusted and is always less than the thickness of the ingot being fed.
− Hence, to reduce the cross-section and increase the length of passing ingot, the rolls are
squeezed. Refer Fig. 4.16.

Fig. 4.6: Hot rolling recrystallisation

− When the metal passes through the rolls, there is change in its grain structure.
− Due to squeezing, the grains are elongated in the direction of rolling and the velocity of
material at the exit is higher than that at the entry.
− After crossing the stress zone, the grains start refining.
4.8.1 Basic Definitions
− The following are the basic terms used related to rolling process :
1. Ingot: Ingot is a larger casting section of suitable shape made for further processing.
2. Bloom: A bloom is a square on rectangular piece formed after reducing ingots. The size
of blooms ranges between 1500 mm x 150 mm to 250 mm x250 mm. Rolling products
from bloom: Structural shapes, Rails, etc.
3. Billets: Billets also formed after reducing ingot but have smaller cross sections. The size
of billet ranges from 50 mm x 50 mm to 150 mm x 150 mm. Rolling product from billets:
Rods, wires, etc.

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4. Slabs: Slabs are metal pieces with rectangular cross section. It has thickness between 50
- 150 mm and width between 300 - 1500 mm. Rolling products from slabs: Sheets,
plates, strips, etc.
4.8.2 Rolling of Various Sections
− The main purpose of rolling is to convert larger sections such as ingots into smaller
sections, which can be used directly in as rolled state or stock for working through other
processes.
− As a result of rolling, there is an improvement in physical properties of cast ingot such as
strength, toughness, ductility, shock resistance, etc.
− Various useful articles like structural sections, sheets, rails, plates and bars, etc. are
produced through rolling.
− Fig. 4.6 shows some commonly used rolled steel sections.

Fig. 4.6: Steel components made from rolling

Fig. 4.7: Various stages of rolling and number of passes for

Converting a steel billet into a round bar
− The desired reduction in the cross-section of the billet and the required shape of the
rolled section are not obtained in a single pass.

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− Fig. 4.7 shows the sequence of rolling and the number of passes required to reduce the
cross-section of a billet to a round steel bar.
− The process starts with the reduction of ingots which have been heated in a gas fired
furnace up to a temperature of 1200 °C.
− The ingots are then taken to the rolling mill where they are rolled into immediate shapes
as blooms, billets or slabs.
− A bloom has a square cross section with minimum size of 150 x 150 mm and a billet is
smaller than bloom and it may have any square section from 38 mm up to the size of
abloom.
− Slabs have a rectangular cross section with a minimum width of 250 mm and minimum
thickness of 38 mm.
4.8.3 Types of Rolling Mills
− According to the number and arrangement of the rolls, rolling mills are classified as
follow:
1. Two-high rolling mill 2. Three-high rolling mill
3. Four-high rolling mill 4. Tandem rolling mill
5. Cluster rolling mill 6. Planetary rolling mill
7. Universal rolling mill
1. Two-high rolling mill:
− It consists of two heavy horizontal rolls placed exactly one over the other.
− The space between the two rolls can be adjusted by raising or lowering the upper roll,
whereas the position of the lower roll is fixed.
− Both the rolls rotate in opposite direction to each other. Refer Fig. 4.8 (a).
− In this type, their direction of rotation is fixed and cannot be reversed.
− There is another type of two-high rolling mill which incorporates a drive mechanism that
can reverse the rotation direction of the rolls.
− This type of rolling mill is called as two-high reversing mill.

Fig. 4.8: Types of rolling mills

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2. Three-high rolling mill:

− It consists of three horizontal rolls positioned directly one over the other.
− The directions of rotation of the upper and lower rolls are same but the intermediate
roll rotates in the opposite direction to each other. Refer Fig. 4.8 (b).
− All the three rolls revolve continuously in the same fixed direction and they are never
reversed.
− The work piece is fed in one direction between the upper and middle rolls and in the
reverse direction between the middle and lower rolls.
− This results in high production rate than the two-high rolling mill.
3. Four-high rolling mill:
− It consists of four horizontal rolls i.e. two of smaller diameter and two of larger diameter
arranged directly one over the other. Refer Fig. 4.8 (c).
− The larger diameter rolls are called back-up rolls and they are used to prevent the
deflection of the smaller rolls, which otherwise would result in thickening of rolled
plates or sheets at the center.
− The smaller diameter rolls are called as working rolls, which concentrate the total rolling
pressure over the metal.
− The common products of these mills are hot or cold rolled sheets and plates.

Fig. 4.8: Types of rolling mills

4. Tandem rolling mill:
− It is a set of two or three stands of rolls set in parallel alignment.
− This facilitates a continuous pass through each one successively without change of
direction of the metal or pause in the rolling process.
− Fig. 4.8 (d) shows the tandem rolling mill.
5. Cluster rolling mill:
− It is a special type of four-high rolling mill.
− In this, each of the two working rolls is backed up by two or more of the larger backup
rolls. Refer Fig. 4.8 (e).
− For rolling hard thin materials, it is necessary to employ work rolls of very small diameter
but of considerable length.
− In such cases, adequate support of the working rolls can be obtained by using a

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6. Planetary rolling mill:

− For the rolling arrangements requiring large reduction, a number of free rotating wheels
are used instead of a single small roll.
− Planetary mill consists of a pair of heavy backing rolls surrounded by a large number of
planetary rolls. Refer Fig. 4.8 (f).

Fig. 4.8 (f): Planetary rolling mill

− The main feature of this mill is that, it reduces a hot slab to a coiled strip in a single pass.
− Each pair of planetary rolls gives an almost constant reduction to the slab.
− The total reduction is the sum of a series of such small reductions following each other
in rapid succession.
− The feed rolls are used to push the slab through a guide into planetary rolls.
− On the exit side planishing mill is installed to improve the surface finish.
7. Universal rolling mill:
− In this type of rolling mill, the metal is reduced by both horizontal and vertical rolls.
− Refer Fig. 4.15 (g).

Fig. 4.8 (f): Universal rolling mill

− The vertical rolls are mounted either on one side or on both sides of horizontal roll stand
which makes the edges of bar even and smooth.
− The horizontal rolls may be either two-high, three-high or four-high arrangement
4.8.4 Effect of Front and Back Tension on Rolling
− Roll forces can cause deflection and flattening of the rolls which adversely affect the
rolling operation.

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− Also, the roll stand (including housing, bearings, chocks, etc.) may stretch due to the roll
forces to such an extent that the roll gap can open up significantly.
− To compensate this deflection and to obtain the desired final thickness, the rolls have to
be set closer than was calculated.
− Roll forces can be reduced by using the following methods :
o To reduce the contact area, use smaller-diameter rolls.
o To reduce the contact area, take smaller reductions in every pass,
o Reduce friction.
o To lower the strength of the material, roll it at high temperature.
− Another effective technique to reduce the roll forces is to apply longitudinal tensions to
the strip during rolling.
− Due to this, the compressive stresses required to deform the material plastically become
smaller.
− As the process requires high roll forces, tensions are particularly important for rolling of
high strength materials.
− The tensions can be applied to the strip either at the entry zone or at the exit zone or
both.
− If the tension is applied at the entry zone, it is called as back tension whereas, if the
tension is applied at the exit zone, it is called as front tension.
− Back tension is applied to the sheet by applying a breaking action to the reel that
supplies the sheet to the roll gap, by some suitable means.
− Front tension is applied by increasing the rotational speed of take up reel.
4.8.5 Principle of Roll Pass
− In addition to flat rolling, different shapes can be produced by shape rolling.
− Straight and long structural shapes like solid bars of different cross-sections, channels,
− I-beams, rails, etc. are produced by passing the stock through specially designed rolls.
− The shape cut into one roll is called as groove and the shape formed when the grooves
of the mating rolls are matched together is called as pass.
− As the materials cross-section is to be reduced non-uniformly, the design of series of
rolls requires considerable experience to avoid external and internal defects.
− By rolling the metal consequently through the passes, the initial square or rectangular
cross section of the ingot (bloom or billet) can be gradually changed to produce a bar of
final desired shape.
− As per the designation, passes are divided into the following three groups :
a. Roughing or breakdown or roll down passes
b. Leader passes
c. Finishing passes
4.9 Roll Piercing or Seamless Tubing
− Roll piercing is a method of producing seamless tubes.

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− Seamless tubing is a popular and economical raw stock for machining because it saves
drilling and boring of parts.
− The piercing machine consists of two tapered rolls, called as piercing rolls. Refer
− Fig. 4.8.

Fig. 4.8: Tube piercing

− During the process, a round heated billet or steel is passed between these rolls over a
mandrel.
− Both the rolls rotate in the same direction and the billet is provided with a small drilled
hole at one end and uniformly heated to about 1100 °C.
− It is then pushed into the two piercing rolls which impart axial and rolling movement to
the billet and force it over the mandrel.
− Hence, the combination of the revolving motion of billet and mandrel together with the
axial advancement of the billet provides a helical tubing effect on the material.
− For production of 12 m length of upto 150 mm diameter rough tubing will take 10 to
30seconds, whereas for tubing of larger diameter (upto 350 mm) second piercing
operation is required.
− As above produced rough tubing is further subjected to rolling, reeling and sizing, to
bring it to the correct shape and size for providing a fine surface finish.
− Such tubes are produced in various metals and alloys such as steel alloys,
aluminium,brass, copper, etc.
4.10 Cold Rolling
− Cold rolling is used for producing bars of all shapes, rods, sheets and strips.
− Cold rolling is generally employed for providing a smooth and bright surface finish tothe
previously hot rolled steel.
− It is used to finish the hot rolled components, to close tolerances and improve their
hardness and toughness.
− Before cold rolling, the hot rolled articles are cleaned through pickling and other
operations.
− The same types of rolling mills, as in hot rolling, are used for cold rolling.

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− The part being rolled is generally annealed and pickled before the final pass is made, so
as to bring it to accurate size and obtain a perfectly clean surface.
4.10.1 Comparison between Hot Rolling and Cold Rolling
Sr. No. Hot rolling Cold rolling
1. Metal is fed into the rolls after being Metal is fed into the rolls when its
heated above recrystallisation temperature is below recrystallisation
temperature. temperature.
2. Hot rolled metal does not show work Cold rolled metal shows work
hardening effect. hardening effect.
3. Coefficient of friction between the Coefficient of friction between rolls
rolls and stock is higher. and stock is relatively lower.
4. Heavy reduction is cross-sectional Heavy reduction in cross-sectional
area is possible. area is not possible.
5. Close dimensional tolerances cannot Section dimensions can be finished to
be obtained. close tolerances.
6. Very thin sections cannot be Aluminum foils up to 0.02 mm can be
obtained. made.
7. Poor surface finish with scale on it. Smooth and oxide free surface can be
obtained.
8. Roll radius is larger. Roll radius is smaller.

4.10.2 Shape Rolling Operations

− In shape rolling process various shapes like structural sections (beams of I, T or C-
sections), sheets, rails, plates and bars are produced.
− Shape rolling process can be divided in two parts :
1. Ring rolling 2. Thread rolling
Ring Rolling:
− Ring rolling is generally used for producing steel tyres of railway car wheels, rotating
rings of jet engines, races of ball bearings, etc.
− The initial material for ring rolling is a pierced billet for producing a thick walled ring.

Fig. 4.9: Ring rolling

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− The ring is placed between driving roll and pressure roll as shown in Fig.4 .9
− The driving roll is fixed but it can rotate freely about its axis.
− The pressure roll applies pressure on the ring towards the driving roll.
− When the ring is gripped, it is caused to rotate and at the same time reduced in
thickness continuously.
− In order to ensure that a circular ring is rolled, a pair of guide rolls must be used.
− Thread Rolling :
− Thread rolling is the most economical and fastest method of making threads.
− It is actually a cold working process in which a plastic deformation takes place.
− No metal is removed and no chips are produced.
− Cold rolling strengthens the thread in tension, shear and fatigue.
Thread Rolling Machines:
− There are three types of thread rolling machines :
o Reciprocating flat die machines.
o Cylindrical die machines.
o Rotary planetary machines having rotary die and one or more stationary
concave-die segments.
− The choice of machine depends upon the size and design of the workpiece, the work
material and the number of pieces to be produced.
1. Reciprocating flat die machines :
− In this process two dies are used. One of them is stationary and another is reciprocating.
− The component to be threaded is rolled between these dies. The moving die
reciprocates in reference to the fixed die as shown in Fig. 4.10 (a) and 4.10 (b).
− In one complete revolution thread is completely formed.
− It is very popular machine, as both right and left hand threads can be rolled.
− This is mainly used for production of threads on nuts and bolts.

(b) Reciprocating flat die machine

Fig. 4.10: Thread rolling

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Advantages of Thread Rolling:

− It is the fastest method of producing a thread, with production rate more than
− 2000 pieces per minute.
− Being a chip less forming process, there is lot of material saving (about 16 to 27 %).
− During thread rolling, the material is strained plastically and work hardened, therefore it
becomes stronger against tension and fatigue.
− A rolled thread is superior to one that has been cut since the process work hardens
− the thread surface and promotes a grain direction which adds to the strength of the
thread.
− Surface finish is better than thread milling and it is in the order of 0.08 to 0.2 pm.
Limitations of Thread Rolling:
− Best suitable only for diameters upto 20 mm.
− Necessary to hold close blank tolerance.
− Uneconomical for low quantities.
− Cannot roll material having a hardness exceeding RC 37.
− Only external threads can be rolled.
Thread Rolling Applications:
− To produce external threads, thread rolling is the best method.
− Electric light bulb, wood screws, machine screws, sheet metal screws, hooks and eyes of
bolts are produced by this method.
− Thread rolling is also used for producing threads on stamped parts.
4.11 Forging
− Forging is the process of shaping heated metal by the application of sudden
blows(hammer forging) or steady pressure (press forging) and makes use of the
characteristic of plasticity of the material.
− Forging is metal forming process which may be done by hand or by machine.
− In case of hand forging, hammering is done by hand; whereas forging by machine
involves the use of dies and it is mostly used in mass production. Refer Fig. 4.11.

Fig. 4.11: Forging process

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− Whatever may be the method of applying pressure for shaping the metal, the primary
requirement is to heat the metal to a definite temperature to bring it into the plastic
state.
− This may done in an open hearth, called as Smith's forge for small jobs or in closed
furnaces for large jobs.
− The shop in which the work is carried out is called as Smithy or Smith's shop.
− The metals which are used in forging process must possess the required ductility.
− We know that ductility refers to the capacity of a material to undergo deformation,
under tension without failure.
− The commonly used forging materials are : Aluminium alloys, copper alloys, low carbon
steels, alloy steels, nickel alloys, tungsten alloys, magnesium alloys, titanium alloys,
beryllium, etc.
4.11.1 Advantages, Disadvantages and Applications of Forging Process
Advantages
− In forging process, grain flow is continuous and uninterrupted. It gives greater strength
and toughness to the forged components. Fig. 4.12 shows three spanners, produced
through three different methods casting, machining and forging. The cast spanner is the
weakest of all, the machined spanner is relatively stronger and the strongest will be the
forged spanner Forged components requires minimum surface finish.
− The forging process gives the high dimensional accuracy.
− Forged components have better mechanical properties like strength, toughness, etc.
− Forged components have better resistance to shock and vibrations.
− Welding of forged parts is easy.

Fig. 4.12 : Spanners produced through three different methods

Disadvantages
− Complicated shapes cannot be forged easily.
− Forging process is mostly suitable for large parts.
− Forging of brittle materials is difficult.
− Due to high cost of forging dies, forging process is costly.
− More noise and vibrations are produced during the process.
Applications
− Forging process is used in the manufacturing of following components :
− Car axles, crankshafts, connecting rods, leaf springs, crane hooks, jet engine turbine dies
and blades.
− Levers, flanges, propellers, hollow bodies, railway wheel disks, tank bottoms.

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− Air-craft and rocket parts, knife blades, bolts, nuts, washers, collars, gear blanks, etc.
4.12 Types of Forging process
− Forging process is classified as follows :
1. According to the working temperature
a. Hot forging
− Most of the forging operations are performed above the recrystallization temperature
but below the melting point of the metals.
− During the process there is deformation of the metal which reduces the strength and
increases the ductility of metal.
b. Cold forging
− For certain products like bolts, rivets, screws, pins, nails, etc. cold forging is also very
common.
− It increases the strength which results from the strain hardening of the component.
2. According to the method of applying the blows
a. Impact forging
− In this method of forging, a machine that applies impact load on the workpiece is called
as forging hammer.
b. Gradual pressure forging
− In this method of forging, a machine that applies gradual pressure on the workpiece
called as forging press.
3. According to the degree to which the flow of workpiece is constrained by the dies
a. Open-die forging
− In this method of forging, the workpiece is compressed between two flat dies which
allows the metal to flow without constraint in a lateral direction relative to the die
surfaces. Refer Fig.4.13 (a).
b. Closed-die or impression-die forging
− In this method, the die surfaces contain an impression or shape which is applied to the
workpiece during the compression. Refer Fig. 4.13 (b).

Fig. 4.13 : Types of forging operations

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− During the operation, some portion of the workpiece flows beyond the die impression to
form a flash. (Flash is excess metal which is trimmed off at the end).
c. Flash less forging
− In this method, the workpiece is completely constrained within the die and no flash is
produced. Refer Fig. 4.13 (c).
− The volume of the initial workpiece must be controlled closely so that it matches with
the volume of the die cavity.
4.13 Open Die Forging
− It is the simplest and important forging process.
− The shapes generated by this process are simple like shafts, disks, rings, etc.
− An example of open-die forging in the steel industry is the shaping of a large square cast
ingot into a round cross-section.
− Open-die forging operations produce rough forms of workpiece hence, subsequent
operations are required to refine the parts to final shape.
− Open-die forging process can be depicted by a solid workpiece placed between the two
flat dies (lower die is fixed and upper die is moving) and reduced in height by
compressing it. This process is called as upsetting or flat-die forging. Refer Fig. 4.14.

Fig. 4.14: Open-die forging

− The deformation of the workpiece is shown in Fig. 4.26. Due to constancy of volume, any
reduction in height of the workpiece increases its diameter.
− In Fig. 4.14 (b) the workpiece is deformed uniformly but practically the workpiece
develops a barrel shape which is called as pancaking or barreling.
− It is caused by the frictional forces at the die-workpiece interfaces and it can minimised
by using an effective lubricant.
− Some of the important operations performed in open-die forging process are as follows :
1. Fullering
− It is performed to reduce the cross-section and redistribute the metal in a workpiece in
preparation for subsequent shape forging.
− It is performed with dies of convex surfaces. Refer Fig. 4.15 (a).
2. Edging
− Its working principle is similar to fullering operation, only the difference is that the dies
have concave surfaces. Refer Fig. 4.15 (b).

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3. Cogging
− It consists of a sequence of forging compressions along the length of workpiece to
reduce the cross-section and to increase the length. Refer Fig. 4.15 (c).
− It is used to produce blooms, slabs, etc. from the cast ingots.
− The dies used in this operation are flat or have slightly contoured surfaces.
− This operation is also called as incremental forging.

Fig. 4.15: Open-die forging operations

4.14 Impression Die or Closed Die Forging
− Impression-die or closed-die forging is performed with dies which contain the inverse of
the required shape of the component. Refer Fig. 4.16.

Fig. 4.16: Closed or impression dies forging

− Initially the cast ingot is placed between the two impressed dies. As the die closes to its
final position, flash is formed by the metal.
− This flash flows beyond the die cavity and into the small gap between the die plates.

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− The formed flash must be cut away from the final component in a subsequent trimming
operation but it performs an important function that, it increases the resistance to the
deformation of the metal.
− The initial steps in the process are used to redistribute the metal in the work part to
achieve a uniform deformation and required metallurgical structure in the subsequent
steps.
− The final steps bring the component to its final geometry. Also, when drop forging is
used, number of blows of the hammer may be used for each step.
− As flash is formed during the process, this process is used to produce more complex
components by using dies.
4.14.1 Comparison between Open-die and Closed-die Forging
Sr. No. Open-die forging Closed-die forging
1. In this method, the workpiece is In this method, the workpiece is
compressed between the two flat compressed between the two
dies. impressed dies.
2. The cost of dies is low. The cost of dies is high.
3. The process is simple. The process is complex.
4. During the process there is poor During the process there is better
utilization of the material utilization of the material.
5. After the process, machining of After the process, machining of
components is required. components is not required.
6. The dimensional accuracy of obtained The dimensional accuracy of obtained
products is not good. products is good.
7. This process is used for low quantity This process is used for high quantity
production. production.
8. It is suitable only for production of It is suitable for production of simple
simple components. and complex components.
4.15 Hammers and other Forging Tools
− Hammers are classified into different groups as shown in Fig. 4.17
− The hammers are used by a Smith in order to give the desired shape to the heated metal
piece.

Fig. 4.17 : Types of hammers

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− Smith's hand hammers are small in size and of following types :

− 1. Ball peen hammer
− 2. Cross peen hammer
− 3. Straight peen hammer
1. Ball Peen Hammer: It is most suitable hammer for hand forging operations. It has cast
steel or forged steel head which is fitted to a wooden handle. One end of the he called
as face i.e. hardened and polished. It is used for general striking and hammering
purpose. Another end is half ball shaped called as peen i.e. used for riveting or burring-
over purpose. Refer Fig. 4.18 (a).
2. Cross Peen Hammer: In this type of hammer, peen is at right angle to the axis handle of
the hammer. It is used for heading, stretching and hammering into the inner of the
component. Refer Fig. 4.18 (b).

Fig. 4.18: Hand or Smith's hammers

3. Straight Peen Hammer: In this type of hammer, peen is parallel to axis of handle of the
hammer. It is used for stretching the metal. Refer Fig. 4.31 (c).
4.15.1 Sledge Hammers
− Sledge hammers are larger in size as compare to hand hammers and of following type
1. Straight peen hammer
2. Cross peen hammer
3. Double ended or double faced hammer.
− Due to large size, weight of sledge hammers is also more than the hand hammers.
− These hammers are used when heavy blows are required to be imparted to the
workpiece.

Fig. 4.19: Sledge hammers

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− To avoid the damage of workpiece surface, the striking surface of the sledge hammer is
made slightly convex and smooth.
− The construction of straight peen and cross peen hammers is similar as discussed in
hand hammers. Refer Fig. 4.19 (a) and (b).
− If the hammer has no peen formation and instead carries flat faces at both ends, then it
is called as double ended or double faced hammer. Refer Fig. 4.19 (c).
4.15.2 Power Hammers
− During forging, heavy components require a great degree of deformation which is not
possible by using hand hammers.
− When forging with power machines, the deformation of the heated metal takes place
either under the action repeated blows or the action of gradually applied pressure.
− Machines which work on the principle of repeated blows are called as forging hammers
or power hammers, whereas those apply gradual pressures are called as forging presses.
− Forging or power hammers are of following types :
1. Spring hammer
2. Pneumatic hammer
3. Steam or air hammer
4. Drop hammer
1. Spring Hammer :
− It has a simple design to regulate the speed and force of its blows.
− It is very light type of power hammer and suitable for small forgings.
− It consists of a heavy rigid frame carrying a vertical projection at its top which act as a
housing for bearing in which leaf or laminated spring oscillates.
− One end of this spring is connected to the connecting rod and other end is connected to
a vertical tup which reciprocates between fixed guides. Refer Fig. 4.20.

Fig. 4.20: Spring hammer

− The connecting rod is attached to on eccentric sheave, which is further connected to the
crank wheel.

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− To operate the hammer, treadle is pressed downwards that makes the sheave to rotate
through the crank wheel and hence, leaf spring starts oscillating in the bearing.
− This oscillation of spring causes the reciprocating motion of the tip and thus, required
blows are provided on the workpiece.
− To adjust the stroke of the connecting rod and intensity of blows, hand lever is used.
2. Pneumatic Hammer :
− Design of pneumatic hammer varies with the different manufacturers.
− Fig. 4.21 shows a commonly used design of pneumatic hammers which consists of
compressor cylinder and ram cylinder.

Fig. 4.21 : Pneumatic hammer

− In these hammers, the compressor cylinder compresses the air and delivers it to the ram
cylinder. By using this compressed air pressure, the ram cylinder piston is actuated.
− A hand lever operates an air valve provided on the air passage from compressor cylinder
to ram cylinder.
− Piston of ram cylinder carries tup at its bottom which can slide inside the fixed guides.
− The compression of the reciprocating cylinder is obtained with the help of crank drive
which is operated by a reduction gear drive.
− Pneumatic hammer can produce 70 to 200 blows/minute.
3. Steam Hammer :
− Steam or air hammers are similar in design to the pneumatic hammers.
− Steam or air hammers are normally consists of double acting cylinder i.e. steam or air is
admitted on both sides of the piston.
− Hence, both the strokes are initiated and performed by the pushing action of
compressed air or steam.
− In this type of hammer, compression of air or steam takes place separately and not
within the hammer.

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− Fig. 4.22 (a) arid (b) shows the working principle of single acting and double acting steam
or air hammers.

Fig. 4.22: Steam or air hammers

− In single acting type, the air or steam is admitted into the cylinder through a part near its
bottom which pushes the piston upwards.
− The steam supply is then cut off when the piston attains the required height and the
outfalls under the gravity on the anvil.
− Before the end of upward stroke, air from atmosphere is admitted into the cylinder
through the air ports, which provides cushioning action and lowers the speed of upward
moving piston.
− In case of double acting type, steam or air is admitted under pressure on both sides of
the piston and both the strokes are operated by the fluid.
4.16 Drop forging
− Drop forging is different from smith's forging as in drop forging closed impressions
rather than open face of flat dies are used
− This process utilizes closed impression die to obtain the required shape of the
component.
− The dies are matched and separately attached to the movable ram and the fixed anvil.
− The forging is produced by impact or pressure, which compels hot and pliable metal to
confirm to the shape of the dies.

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− During the operation, there is a drastic flow of metal in the dies caused by repeated
blows of hammers on the metal.
− To ensure proper flow of the metal during the intermittent blows, the operation is
divided into a number of steps.
− Each step changes the metal form gradually, controlling the flow of the metal until the
final shape is obtained.
− The number of blows required varies according to the size and shape of the part, forging
quality and required tolerances.
− The equipment used for applying the blows is called as drop hammer.
− Three types of drop hammers are used in making drop forgings :
o Board or gravity hammer
o Air-lift hammer
o Power drop hammer or steam hammer
− Fig. 4.23 shows the principle of a board or gravity hammer.

Fig. 4.23 : Principle of a board or gravity hammer

− The drop forging die consists of two halves i.e. lower half and upper half.
− The lower half of the die is fixed to the anvil of the machine while upper half is fixed to
the ram.
− The heated stock or the workpiece is kept in the lower die while the ram delivers four to
five blows on the metal in quick succession, so that the metal spreads and fills the die
cavity.
− The force of the blow can be varied by changing the distance of the fall.
− The anvil which must absorb the blow is generally 20 times heavier than the hammer.
− A board hammer which works rapidly, gives over 300 blows per minute.
− Board hammer can do a wide variety of work and they are less expensive as compare to
the others.
− Components manufactured by drop forging are car axles, crankshafts, connecting rods,
leaf springs, crane hooks, jet engine turbine dies and blades.
Disadvantages of Drop Forging:
− The boards are liable to frequent breakage.

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− The intensity of blow cannot be controlled during the stroke.

− Dimensional accuracy is less.
− The life of the hammers and dies is less.
− More noise and vibrations are produced during the operation.
4.16.1 Press Forging
− It is done in presses rather than by using hammers.
− The action is relatively slow squeezing instead of delivering heavy blows and penetrates
deeply because it gives the metal time to flow.
− Press forgings are shaped at each impression with a single smooth stroke and they stick
to the die impression more rigidly.
− Press forgings are generally more accurate dimensionally than drop forgings.
− Press for forgings may be of two types i.e. hydraulic and mechanical press.
− The dies used carry relatively less draft and hence more complicated shapes can be
forged.
− The life of the presses and dies is longer than that of the hammer and dies used on
them.
− The process does not require highly skilled operator because the speed, pressure and
travel of the die are automatically controlled.
− There are less vibrations and noise as compared to hammering.
− Presses of 500 to 600 tonnes capacities are generally used.
− Press forging is used for the manufacturing of large levers, flanges, toothed wheels,
crankshafts, propellers, hollow bodies, railway wheel disks, tank bottoms, panels and
other bodies of air-craft and rocket bodies.
4.16.2 Machine or Upset Forging
− Machine forging is also called as hot heading.
− It consists of applying pressure longitudinally on a hot bar, which is gripped firmly
between grooved dies, to upset a required portion of its length.
− All forgeable metals can be upset through this process.
− They may have any shape of cross-section, but round shape is most commonly used.
− The equipment used for this type of forging is known as forging machine or up setter.
− The machine provides forging pressure in a horizontal direction.
− The dies are so designed that, the complete operation is performed in several stages and
the final shape is attained gradually.
− The operation is performed by using die and punch which is called as heading tool, as
shown in Fig. 4.24.

Fig. 4.24 : Upset forging

− The die is either made hollow to receive the round bar through it or in two parts to open
out and receive the bar.

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− Between the heading tool and the die, a mechanical stop is placed which determine the
correct projecting length of the bar.
− After the bar has been gripped firmly, with its correct length projecting outside, the stop
is replaced and the heading tool is advanced into the die.
− Many such strokes are required to complete the upsetting.
− Forging of the ring and rod types with all kinds of heads and shoulders such as be bolts,
nuts, washers, collars, pinion gear blanks, etc. can be easily produced by this process.
Advantages of Machine Forging:
− The quality of machine forging is better than the other forging methods.
− The dies carry no draft; hence flash is not produced on the parts.
− Better dimensional accuracy can be obtained.
− With the help of this forging process piercing can also be done with considerable
accuracy.
− Forging machines have higher productivity and their maintenance is less expensive than
the other methods.
− The process can be automated.
Disadvantages of Machine Forging:
− Due to material handling difficulties, heavier components cannot be forged easily.
− The components having diameter more than 250 mm cannot be forged by this process.
− Intricate and unsymmetrical components are difficult to be forged.
− Tooling cost is high.
4.16.3 Roll Forging
− Roll forging process consists of placing raw stock between two roll dies which are of
semi-cylindrical form and are grooved to impart a desired shape to the workpiece being
forged.
− Thee roll dies are carried on roll shafts and rotate continuously towards the operator.
Refer Fig. 4.25 (a) and (b).

Fig. 4.25: Principle of operation of a roll forging machine

− Fig. 4.49 (a) shows the rolls in an open condition, with the heated workpiece in the tong
and resting on the guide.
− In Fig. 4.49 (b) the rolls are brought together, with the stock gripped in the grooves of
the rolls.

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− The rolling action forces the stock towards the operator.

− When the dies are again in an open condition the stock is placed in appropriate grooves
of the rolls and the operations are repeated until the required shape is not obtained.
− This process is also used to make large reductions in the cross-section and distribution of
the metal of a billet, hence saving considerable work in the forging hammer or press.
− By using roll forging, parts such as knife blades, automobile drive shafts, axles, leaf
springs and gear-shift levers are made.
4.17 Forging Operations
− A number of operations are used to change the shape of the raw material to the finished
form. A typical smith forging operations are as follows :
1. Upsetting 2. Drawing out or drawing down
3. Cutting 4. Bending
5. Punching and Drifting 6. Setting down
7. Welding
1. Upsetting :
− Upsetting is also called as jumping or heading.
− It is a process through which the cross-section of a metal piece is increased with a
corresponding increase in its length.
− When a metal is sufficiently heated, it acquires the plastic stage, so that it becomes soft.
− If some pressure (blows) is applied to it, then the metal tends to swell or increase in its
dimensions at right angles to the direction of application of force with corresponding
reduction in its dimensions.

Fig. 4.26: Upsetting a bar Fig. 4.27: Drawing out

− This is what actually takes place during upsetting or jumping a metal part. Refer Fig 4.50
2. Drawing out or drawing down :
− Drawing out is exactly a reverse process to that of upsetting.
− It is employed when a reduction in thickness, width of a bar is desired with a
corresponding increase in its length.

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− The desired effect is obtained by the use of either the peen of a cross peen hammer, a
set of fullers or a pair of swages.
− Fig. 4.51 shows the drawing out operation by using top and bottom fullers.
3. Cutting :
− Cutting-off is a form of a chiseling whereby a long piece of stock is cut into several
specified lengths, or a forging is cut-off from its stock.
− A notch is first made about one half the thickness or diameter of the stock.
− After that, the workpiece must be turned through an angle of 180° and the chisel is
placed exactly opposite the notch.
− The required length of metal can then be cut-off by giving the chisel a few blows with a
sledge hammer.
4. Bending :
− Bending is an important operation in smith forging and it is very frequently used.
− It may be classified as angular or curvilinear.
− Any required angle or curvature can be made through this operation.
− Bending operation is carried out on the edge of the anvil or on the perfectly square edge
of a rectangular block.
− For making a right angle bend, particular portion of the stock is heated and jumped on
the outer surface.
− When metal is bent, the layers of metal on the inside are compressed and those on the
outside are stretched.
5. Punching and Drifting :
− The term punching refers to the operation in which a punch is forced though a
workpiece to produce a hole.
− The workpiece is first heated and then placed on the anvil face.
− The punch is then forced into it upto about half its thickness.
− The workpiece is then turned upside down and placed over a tool called as bolster.
− The punch is again forced into the workpiece and made to pass through by hammering.
− Punching without using a die, is generally followed by drifting.
− In drifting, a tool known as drift, is made to pass through the punched hole to produce a
finished hole of the required size.
6. Setting down :
− Setting down is the operation through which the rounding of a corner is removed, to
make it square by using a set hammer.
− By putting the face of the hammer over the round portion, formed by bending or
fullering of the corner and hammering it at the top a local reduction in thickness takes
place resulting in sharp corner.
− Hence, finishing operation is performed through which the unevenness of a flat surface
is removed by using a flatter or a set hammer.
7. Welding :
− Welding or shutting is the principle operation performed by the smith.
− The metal which remains pasty over a wide range of temperature is most easily welded.
− For production of sound weld, the surfaces in contact must be perfectly clean, both
mechanically and chemically, so that cohesion will take place when the metal is in
aplastic state.

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− A protection to the metal is a coating of flux which covers the surfaces of the metal and
prevents oxidation.
− A forge weld is made by hammering together the ends of two bars which have been
formed to the corrected shape and heated to a welding temperature in a forge fire.
− The method of preparing the metal pieces for welding is called as scarfing.
4.18 Extrusion
− Extrusion is a compression process in which the work metal is forced to flow through a
small opening which is called as die to produce a required cross-sectional shape.
− The extrusion process is similar to squeezing toothpaste or cream from a tube.
− Almost any solid or hollow cross-section may be produced by extrusion process.
− As the geometry of the die remains same during the operation, extruded parts have the
same cross-section.
− During the process, a heated cylindrical billet is placed in the container and it is forced
out through a steel die with the help of a ram or plunger.
− The products made by extrusion process are tubes, rods, railings for sliding doors,
structural and architectural shapes, door and window frames, etc.
− Extrusion process is suitable for the non-ferrous alloys, steel alloys, non-ferrous metals,
stainless steel, etc.
− Extrusion process is carried out on horizontal hydraulic press machines which are rated
from 250 to 5500 tonnes in capacity.
− Extrusion process is classified as follows :
1. According to physical configuration
a. Direct (Forward) extrusion
b. Indirect (Backward) extrusion
2. According to working temperature
a. Hot extrusion
b. Cold extrusion
4.18.1 Direct Extrusion
− Direct or forward hot extrusion is most widely used and the maximum numbers of
extruded parts are produced by this method.
− Fig. 4.28 shows the direct extrusion process in which the raw material is a billet.
− A billet is heated to its forging temperature and fed into the machine chamber.
− Pressure is applied to the billet with the help of ram or plunger which forces the material
through the die.
− The length of extruded part will depend on the billet size and cross-section of the die.
− The extruded part is then cut to the required length.
− As the ram approaches the die, a small portion of billet remains which cannot be forced
through the die opening. This extra portion is known as butt which is separated from the
product at the end.
− When the billet is forced to flow through the die opening, there is friction between the
workpiece and chamber walls. This friction is overcome by providing additional ram
force. This is the major problem with this process.
− To overcome this problem oxide layer is provided on the billet or dummy block is used
between the ram and billet.

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− Direct extrusion process is also used to produce hollow or semi-hollow sections.

Fig. 4.28: Direct extrusion

− To produce hollow sections, by direct extrusion process, a mandrel is used. Refer Fig.
4.28
− When the billet is compressed, the material is forced to flow through the gap between
the mandrel and die opening. This results in tubular cross-section.
4.18.2 Indirect Extrusion
− Indirect extrusion is also called as backward extrusion.
− In this type, the ram or plunger used is hollow and as it presses the billet against the
back wall of the closed chamber, the metal is extruded back into the plunger. Refer Fig.
4.29.
− It involves no friction between the metal billet and the chamber because the billet does
not move inside the chamber.

Fig. 4.29 : Indirect or backward or reverse extrusion

− As compared to direct extrusion, less total force is required in this method.

− But the equipment used is mechanically complicated in order to support the passage of
the extruded shape through the center of the hollow ram.
− Indirect extrusion is also used to solid as well as hollow components. For producing solid
parts ram is hollow whereas for producing hollow parts ram is solid.
4.18.3 Cold Extrusion (Impact Extrusion)
− The most common cold extrusion process is impact extrusion.
− Various daily use products such as tubes for shaving creams, tooth paste and paints,
condenser cans and such other thin walled products are impact extruded.

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Manufacturing process-II (2141908) 4. Metal Shaping and Forming

− The raw material is in slug form which have been turned from a bar or punched from a
strip.
− By using punch and dies, the operation is performed.
− The slug is placed in the die and struck from top by the punch operating at high pressure
and speed. Refer Fig. 4.30.

Fig. 4.30: Principle of impact extrusion

− The metal flows up along the surface of the punch, forming a cup shaped component.
− When the punch moves up, to separate the component from the punch compressed air
is used.
− At the same time, a fresh slug is fed into the die.
− The rate of production is fairly high i.e. 60 components per minute.
− This process is used only for soft and ductile materials such as lead, tin, aluminum, zinc
and some of their alloys.
− The main advantages of this process are its speed, product uniformity and no wastage.
4.18.4 Hydrostatic Extrusion
− In this type of extrusion process, the billet is surrounded by a working fluid which is
pressurised by the ram to apply the extrusion force.
− In this process, hydraulic fluid remains between the billet and the chamber walls hence
eliminating the contact between them. Also, it avoids the friction between the metal
billet and the walls of the chamber.
− Fig. 4.31 shows the working principle of hydrostatic extrusion.
− Due to absence of wall friction, extrusion of very long billets or even wires and large
reductions can be taken.

Fig. 4.31: Hydrostatic extrusion

− During the process, the ram does not directly act on the billet, instead of that, it acts on
the hydraulic fluid which forces the billet through the die and produces the extrusions.

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 4. Metal Shaping and Forming Manufacturing process-II (2141908)

− The materials which cannot be extruded successfully by conventional methods can be

extruded by this process.
4.19 Defects in Extrusion
− Following are the three basic categories of extrusion defects :
i. Center cracking ii. Surface cracking iii. Piping defect
i. Center cracking
− It is commonly called as internal breakage, cheveron cracking, arrowhead fracture and
center burst.
− As the workpiece is being extruded from the die, stresses in the work break the material.
− It causes cracks to form along the central axis of extruded part. Refer Fig. 4.59.
− This defect occurs due to difference in metal flow of central region and outer region.
− Surface cracking
− In surface cracking, excessive stresses on the surface of the extruded part cause the
breakage on the surface. Refer Fig. 4.60.
− These cracks usually occur along the grain boundaries.
− Surface cracking occurs due to high extrusion temperature, friction and speed.
− Piping defect
− Piping defect is commonly called as tail pipe or fish tailing defect and occurs during
direct extrusion at the end opposite to the die.
− Piping defects results due to improper metal flow during the extrusion operation.
− A funnel shaped void of material at the end of the work is seen in this defect.
4.20 Wire Drawing
− Drawing is an operation in which the cross-section of a bar, rod or wire is reduced by
pulling it through a die opening.
− The general features of the drawing process are similar to extrusion. But the difference
is that, in drawing the workpiece is pulled through the die whereas in extrusion
workpiece is pushed through the die.
− During the process, tensile as well as compressive stresses are produced in the material.
− The main difference between the bar drawing and wire drawing is the stock
size(workpiece size). Bar drawing is used for large diameter (bar and rod) stock whereas
wire drawing is used for small diameter stock.

Fig. 4.32(a) : Wire drawing

− Wire sizes upto 0.03 mm can be drawn by wire drawing process.
− The process consists of pulling the hot drawn bar or rod through a die of which the bore
size is similar to the finished product size.

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Manufacturing process-II (2141908) 4. Metal Shaping and Forming

− Depending upon the material to be drawn and the amount of reduction required, total
drawing can be accomplished in a single die or in a series of successive dies.
− One end of the rod to be drawn into wire is made pointed, entered through the die and
gripped at the other end by using tongs.

Fig. 4.32(b): Wire drawing

− After pulling a certain length, this end is wound to a reel or draw pulley.
− When the pulley or reel is rotated, the rod is pulled through the die and its diameter
reduces. Refer Fig. 4.32 (a) & (b)
− The die is made of highly wear resistant material.
− Generally, tungsten carbide is used for die making.
− The die made of tungsten carbide is suitably supported in a die holder which is made of
mild steel or brass.
4.21 Tube Drawing
− As the initial tubing has been produced by other processes like extrusion, drawing can
be used to reduce the diameter or wall thickness of seamless tubes and pipes.
− Tube drawing can be carried out either with mandrel or without mandrel
− The simplest method of producing tubes and pipes is shown in Fig. 4.65 (a) in which
mandrel is not used. This method is also called as tube sinking.
− In tube sinking method there is no control over the inner diameter and wall thickness of
tube.

Fig. 4.33: Tube drawing

− To overcome this drawback, mandrels are used in the process.

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4. Metal Shaping and Forming Manufacturing process-II (2141908)

− Fig. 4.33(b) shows tube drawing with mandrel. In this method, mandrel is fixed and
attached to a long support bar to produce inside diameter and wall thickness during the
process.

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Page 4.38 Darshan Institute of Engineering & Technology, Rajkot