Raya University

Engineering and Technology College

Manufacturing Engineering Department

Advanced Manufacturing Process [MaEngn5301]

CHAPTER-5: ADVANCED METAL FORMING PROCESSES

 ADVANCED METAL FORMING PROCESSES

Lesson Objectives
In this chapter we shall discuss Learning Activities
the following: 1. Look up
 Introduction
2.
Keywords
View Slides;
 High energy rate
3. Read Notes,
forming (HERF) 4. Listen to
process, lecture
 Stretch forming,
 Contour roll forming,
 Superplastic forming,
 Pressing and Sintering,
 Isostatic pressing
 Introduction to Metal Forming

 The desired shape and size are obtained through plastic deformation of

the material.

 Very economical process as the desired shape, size and finish can be

obtained without significant loss of material.

 Also improves the strength of the product through strain hardening

High Energy Rate Forming (HERF) Process
 HERF; Principle/ Important Features

 The energy of deformation is delivered at a much higher rate than in

conventional practice.
 Larger energy is applied for a very short interval of time.
 The velocity of deformation is very large and hence these are also
called High Velocity Forming (HVF) processes.
 Many metals tend to deform more readily under extra fast
application of force.

 Large parts can be easily formed by this technique.

 Factors to be considered while selecting an HERF process:

 Size of work piece

 Geometry of deformation
 Behavior of work material under high strain rates
 Energy requirements/ source
 Cost of tooling / die
 Cycle time
 Overall capital investment
 HERF Vs Conventional Forming

Conventional Forming:

 For this operation, usually force is applied to the metal to be work upon using simple
hammer blow or power press.

 Deforming metals by using heavy tools moving at relatively low velocity.

 These techniques includes methods such as:
 Forging

 Extrusion
HERF Vs Conventional Forming
HERF Vs Conventional Forming

Flanged and deep

recessing parts

Plane Contoured
 Advantages of HERF Processes

 Production rates are higher, as parts are made at a rapid rate

 Die costs are relatively lower

 Tolerances can be easily maintained

 Versatility of the process it is possible to form most metals including difficult to form

metals.

 No or minimum spring back effect on the material after the process

 Advantages of HERF Processes

 Production cost is low as power hammer (or press) is

eliminated in the process
 Complex shapes profiles can be made much easily.
 The required final shape/ dimensions are obtained in one
stroke (or step), thus eliminating intermediate forming
steps and pre forming dies.
 Suitable for a range of production volume such as small
numbers, batches or mass production
 HERF ;Limitations

 Highly skilled personnel are required.

 Not suitable to highly brittle materials

 Source of energy (chemical explosive or electrical) must be handled
carefully.
 Governmental regulations/ procedures / safety norms must be
followed.
 Dies need to be much bigger to withstand high energy rates and
shocks and to prevent cracking.
 Controlling the application of energy is critical as it may crack the
die or work.
 HERF; Application

 In ship building to form large plates parts (up to 25 mm thick)

 Bending thick tubes/ pipes (up to 25 mm thick).
 Crimping (compress into small folds) of metal strips.
 Radar dishes.

 Elliptical domes used in space applications.

 Cladding of two large plates of dissimilar metals.

Types of HERF Processes: Types of HERF Processes:

1.Explosive Forming

2.Electro Hydraulic Forming

3.Magnetic Pulse Forming
 Explosive Forming

 A punch in conventional forming is replaced by an explosive charge.

Explosives used can be:
 High energy chemicals like Dynamite.
 Gaseous mixtures
 Propellants.
Types of explosive forming:
1) Unconfined type or Stand off technique
2) Confined type or Contact technique
 Unconfined type (Stand off technique)

 The w/p is firmly supported on

the die and the die cavity is
evacuated.
 A definite quantity of explosive
is placed suitably in water
medium at a definite stand off
distance from the w/p.
 On detonation of the explosive
charge, a pressure pulse (or a
shock wave) of very high
intensity is produced
 Unconfined type (Stand off technique)

 A gas bubble is also produced which expands spherically and

then collapses.

 When the pressure pulse impinges against the w/p, the metal is
deformed into the die with a high velocity of around 120 m/s

(430 km/h)

 The vacuum is necessary in the die to prevent

adiabatic heating of the work which may lead to
oxidation
 Process parameters

 Type and amount of explosive: wide range of explosives

are available.
 Stand off distance SOD --(Distance b/n w/p and explosive):
Optimum SOD must be maintained.
 The medium used to transmit energy: water is most widely
used.
 Work size
 Work material properties
 Vacuum in the die
 Unconfined type (Stand off technique)

Limitations:

 Optimum SOD is essential for proper

forming operation.
 Vacuum is essential & hence it adds to the
cost.
 Dies must be larger & thicker to withstand
shocks.
Applications:
 Not suitable for small & thin works.
 Explosives must be carefully handled
 Ship building,
 Radar dish,
according to the regulations of the
government  Elliptical domes in
space applications
 Confined System (Contact Technique)

Reading assignment..????
 Electro Hydraulic Forming

Principle

 A sudden electrical discharge in the form of sparks is produced between

electrodes and this discharge produces a shock wave in the water medium.

 This shock wave deforms the work plate and collapses it into the die.
Working Principle:
1. A sudden electrical discharge (sparks) occurs between the
electrodes.
2. This discharge produces a shockwave in the water medium.
3. The shockwave deforms the workplate, collapsing it into the
die.
4. The characteristics of EHF are similar to those of explosive
forming, but instead of chemical explosives, a capacitor
bank stores the electrical energy1
 Electro Hydraulic Forming

 This process is similar to those of explosive forming.

 The major difference, however, is that a chemical explosive is replaced by a

capacitor bank, which stores the electrical energy.

 The capacitor is charged through a charging circuit.

 When the switch is closed, a spark is produced b/n electrodes and a shock wave

or pressure pulse is created.

 The energy released is much lesser than that released in explosive

 Electro Hydraulic Forming

Process Characteristics:

 Stand off distance: It must be optimum.

 Capacitor used: The energy of the pressure pulse depends on the size
of capacitor.

Transfer medium: Usually water is used.

 Vacuum: the die cavity must be evacuated to prevent adiabatic heating of the

work due to a sudden compression of air

Material properties with regard to the application of high rates of strain

 Electro Hydraulic Forming

Advantages

 Better control of the pressure pulse as source of energy is electrical- which can

be easily controlled.

 Safer in handling than the explosive materials.

 More suitable if the work size is small to medium.
 Thin plates can be formed with smaller amounts of energy.
 The process does not depend on the electrical properties
of the work material.
 Electro Hydraulic Forming

Limitations:

 Suitable only for smaller works

 Need for vacuum makes the equipment more complicated

 Proper SOD is necessary for effective process

Applications:

 They include smaller radar dish, cone and other shapes in thinner and small

works.
 Electromagnetic Forming

 The electrical energy stored in a capacitor bank is used to

produce opposing magnetic fields around a tubular w/p,

surrounded by current carrying coils.

 The coil is firmly held and hence the w/p collapses into the die

cavity due to magnetic repelling force, thus assuming die shape

 Electromagnetic forming

 The electrical energy is stored in the capacitor bank.

 The tubular work piece is mounted on a mandrel having the die

cavity produce shape on the tube.

 A primary coil is placed around the tube and mandrel assembly.

 When the switch is closed, the energy is discharged through the coil
 The coil produces a varying magnetic field around it.
 In the tube a secondary current is induced, which creates its own
magnetic field in the opposite direction
 The directions of these two magnetic fields oppose one another and
hence the rigidly held coil repels the work into the die cavity
 The work tube collapses into the die, assuming its shape
 Electromagnetic forming

Process parameters:

 Work piece size

 Electrical conductivity of the work material

Size of the capacitor bank

The strength of the current, which decides the strength of the magnetic field and
the force applied

Insulation on the coil

 Electromagnetic forming

Advantages:

 Suitable for small tubes

 Operations like collapsing, bending and crimping can be easily

done.

Electrical energy applied can be precisely controlled and hence the process is
accurately controlled.

The process is safer compared to explosive forming.

 Electromagnetic forming

Limitations:

 Applicable only for electrically conducting materials.

 Not suitable for large work pieces.

Rigid clamping of primary coil is critical.

Shorter life of the coil due to large forces acting on it
Applications:

 Crimping of coils, tubes, wires

 Bending of tubes into complex shapes

 Bulging of thin tubes.

 Stretch Forming

 A piece of sheet metal is stretched

and bent is simultaneously over a
die to form large contoured parts.
 Stretch forming is performed on a
stretch press, in which a piece of
sheet metal is securely gripped
along its edges by gripping jaws.
 Stretch Forming

 The gripping jaws are each attached to a

carriage that is pulled by pneumatic or

hydraulic force to stretch the sheet.

 The tooling used in this process is

a stretch form block, called a form
die, which is a solid contoured
piece against which a sheet metal
will be pressed.
 Stretch Forming

Advantage:

 Approximately 70% less force is needed than that required for

conventional forming.
 Because stretch forming is done on the entire area of the workpiece,
there is little likelihood of buckles and wrinkles. Tensile strength is
increased uniformly by approximately 10%.
 Hardness is increased by approximately 2%. Springback is greatly
reduced. There is some springback, but it is easily controlled by over
forming.
 Residual stresses are low in stretch-formed parts.
 Stretch Forming

 It is seldom suited to progressive or transfer operations.

 It
is limited in its ability to form sharp contours and
reentrant angles. It is at its best in forming shallow or
nearly flat contours.
 If the piece is not pinched between mating dies, there is no
opportunity to coin out or iron out slight irregularities in the surface of the
metal.
 In some applications, especially in stretch wrapping, the
process is slower than competitive processes, and it is not
suited to high volume production. However, stretch draw
forming with mating dies can be done as rapidly and
Stretch Forming
 Contour roll forming

 Known as roll forming or cold

roll forming
 It is a continuous process for
forming metal from sheet, strip
or coiled stock into desired
shape of uniform cross section
by feeding the stock through a
series of roll stations equipped
with contoured rolls.
 Rollers are carefully crafted
using a flower pattern, which
identifies the sequential
changes to the metal strip. The
shape of each roller is created
from the individual sections of
the flower pattern.
 Contour roll forming

Roll forming is superior to other metal forming processes and has

advantages over aluminium extrusions, for many reasons.

 Contour roll forming

Advantages:

 Can produce more parts with greater uniformity and

consistency throughout the length of the part.

 Eliminates multiple stage operations, trim scrap, and slitting

burrs.
 Super Plastic forming (SPF)

 is described as the capability of a material to undergo extensive tensile

deformation.

 In a tensile test, elongations of more than 200-300% are generally

referred to as superplastic deformation.

 is a near net shape process which typically uses high temperature and gas

pressure to form particular materials onto a single step mold.

 is receiving increasing interest as a process capable of radically

extending the limitations associated with the more conventional
 Super Plastic forming (SPF)

 The large tensile elongations and typically low flow stresses

associated with a superplastic metal permit the forming of

complex parts using methods and forming pressures not

previously possible.

 SPF process is reliant upon a stable, duplex, fine grain

material, which can be elongated to strain levels up to and
 Super Plastic forming (SPF)

 To form a shape, the blank is placed between the forming tool and reactive

plate, with time allowed to achieve the forming temperature.

 The press is then closed and an adequate reactive load is applied to form a gas

tight seal around the tool’s periphery.

 Injection argon gas, between the component blank and the reactive plate, as

dictated by a calculated strain rate sensitive pressure/time cycle, forms the

component. At the end the cycle gas is released and the component is removed
 Super Plastic forming (SPF)

Advantages:

 Complex monolithic structures can be produced as single or multi items in one

tool at one forming cycle.

 This reduces component part count, forming cycle. This reduces component

part count, spreads press set up costs, removes the need for assembly rivets and

hence reduces weight and cost.

SPF
products
 Reading Assignment

Pressing and Sintering,

Isostatic pressing

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