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Metal Forming

The document discusses various metal forming processes including bulk metal forming processes like rolling, forging, extrusion, and drawing as well as sheet metalworking processes like bending, drawing, and shearing. It also covers important concepts in metal forming like material behavior, the effect of temperature and strain rate, and the role of friction and lubrication.

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abdsu75
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280 views

Metal Forming

The document discusses various metal forming processes including bulk metal forming processes like rolling, forging, extrusion, and drawing as well as sheet metalworking processes like bending, drawing, and shearing. It also covers important concepts in metal forming like material behavior, the effect of temperature and strain rate, and the role of friction and lubrication.

Uploaded by

abdsu75
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Metal Forming

Overview
• Process Classification
– Bulk Deformation Process
– Sheet Metalworking
• Material Behaviour in Metal Forming
– Flow Stress
– Average Flow Stress
• Temperature in Metal Forming
• Effect of Strain Rate
• Friction & Lubrication
Bulk Metal Forming
• Rolling - compression process to reduce the
thickness of a slab by a pair of rolls.
• Forging - compression process performing
between a set of opposing dies.
• Extrusion - compression process sqeezing
metal flow a die opening.
• Drawing - pulling a wire or bar through a
die opening.
Bulk Metal Forming

Rolling Forging

Extrusion Drawing
Sheet Metalworking
Forming on metal sheets, strips, and coils. The
process is normally a cold working process
using a set of punch and die.
• Bending - straining of a metal sheet to form
an angle bend.
• Drawing - forming a sheet into a hollow or
concave shape.
• Shearing - not a forming process but a
cutting process.
Sheet Metalworking
Material Behavior in Metal Forming
Y f  K n

K n
Yf 
1 n

Yf Flow Stress
 Maximum strain
for forming process
K Strength coefficient
Y f Average flow stress
Temperature in Metalworking
• Cold working
– Pros
• better accuracy
• better surface finish
• strain hardening increases strength and hardness
• grain flow during deformation provides directional
properties
• no heating is needed
– Cons
• higher forces and power are required
• surface should be cleansed
• ductility and strain-hardening limits the extent of
forming
Temperature in Metalworking
• Warm working - temperature between room
temperature and recrystallization temperature,
roughly about 0.3 Tm
– Pros against cold working
• Lower forces and power
• more intricate work geometries possible
• need for annealing may be reduced/eliminated.
Temperature in Metalworking
• Hot working - Deformation at temperature
above recrystallization temperature
typically between 0.5Tm to 0.75Tm
– Pros
• larger deformation possible
• lower forces and power
• forming of room temperature low ductility material
is possible
• isotropic properties resulted from process
• no work hardening
Temperature in Metalworking
• Isothermal Forming - preheating the tools to
the same temperature as the work metal.
This eliminates the surface cooling and the
resulting thermal gradient in the workpart.
• Normally applies to highly alloyed steels,
titanium alloys and high-temperature nickel
alloys.
Effect of Strain Rate
Y f  C m
 strain rate
The strain rate is strongly
affected by the temperature.

Y f  A n  m
A = a strength coefficient
Friction and Lubrication
• Friction is undesirable:
– retard metal flow causing residual stress
– increase forces and power
– rapid wear of tooling
• Lubrication is used to reduce friction at the
workpiece-tool interface

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