Experiment name: Introduction
Stage: Fourth stage-7th semester
Year: 2024-2025
Lana Ibrahim Hassan
[email protected] Identify and describe various metal
forming processes, including
forging, extrusion, rolling, and
drawing .
Learning Discuss the importance of material
properties such as ductility, yield
strength, and work hardening in
outcome relation to metal forming.
Recognized the classify of metal
forming processes according to row
material and temperature.
It is a large group of manufacturing processes
in which plastic deformation is used to change
the shape of metal workpieces
What is The tool, usually called a die, applies
stresses that exceed the yield strength of
metal the metal
forming?
The metal takes a shape determined by
the geometry of the die
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Typical
regions that
can be
observed in
a stress-
strain curve
are:
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High Ductility: Allows for significant
plastic deformation without cracking,
enabling complex shapes.
Material Good Strength: A balance of yield and tensile
strength is important for durability while still
Properties allowing for deformation.
Optimal Hardness: Sufficient hardness to
in Metal resist wear during forming, but not so hard that
it becomes brittle or difficult to work with.
Forming High Toughness: Ability to absorb energy and
resist fracture, especially in applications subject
to impacts.
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Typical regions that can be observed in a stress-strain
curve are:
6
Excellent Formability: Materials that can
easily be shaped with minimal defects or
failures are ideal for a variety of forming
processes.
Conti…
Temperature Sensitivity: Favorable response
to temperature changes, allowing for improved
ductility and formability at elevated
temperatures.
Isotropy: Uniform properties in all
directions help predict behavior during
forming and reduce the risk of defects.
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Basic Types of Metal Forming Processes
Bulk deformation Sheet metal working
Rolling processes
Bending operations
Forging processes
Deep or cup drawing
Extrusion processes
Shearing processes
Wire and bar drawing
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• Bulk deformation processes : involve
reshaping large volumes of metal
Bulk (Cylindrical billets, Rectangular bars)
Deformatio through plastic deformation, to produce
components with desired shapes and
n dimensions.
• "Bulk" refers to work parts with relatively
Processes low surface area-to-volume ratios
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(a) Rolling (b) Forging
(c) Extrusion (d) Wire and bar drawing
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• Sheet metalworking involves processes that shape and
form thin metal sheets into various products, typically
ranging from 0.2 mm to several millimeters in thickness.
• High surface area-to-volume ratio of starting metal,
Sheet which distinguishes these from bulk deformation.
Metalworking • Often called pressworking because these operations are
performed on presses which the :
• Parts are called stampings
• Usual tooling punch and die
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Bending Deep drawing
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Shearing
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First lecture/Introduction
Temperature in Metal Forming
• Temperature plays a significate role in metal forming processes,
influencing material behavior and the outcomes of various operations.
• Proper temperature control can enhance ductility, reduce strength, and
any deformation operation can be accomplished with lower forces and
power.
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Three temperature ranges in metal forming:
• Cold working
• Warm working
• Hot working
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• Cold forming processes are conducted at
or near room temperature, typically
below the recrystallization temperature
of the material.
Cold
• These operations are near net shape that
Working usually required minimum machining or
net shape processes that no required
machining.
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Benefits of cold forming
• Improved Surface Finish
• Higher Dimensional Accuracy
• No preheating needed
• Strain hardening increases strength and hardness
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Limitations of cold forming
• Reduced ductility.
• Higher forces and power required.
• Risk of cracking.
• In some cases, metal must be annealed after further deformation be
accomplished.
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• Performed at temperatures above room
temperature but below recrystallization
temperature
• Dividing line between cold working and
Warm warm working often expressed in terms
of melting point:
forming • 0.3Tm, where Tm = melting point
(absolute temperature) for metal
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Advantage & limitation
Advantages
• Lower forces and power than in cold working
• More intricate work geometries possible
• Need for annealing may be reduced or eliminated
Limitation
• Workpiece must be heated
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• Deformation at temperatures above the
recrystallization temperature.
• The recrystallization temperature for a given
metal is about one-half of its melting point on
Hot the absolute scale.
forming • In practice, hot working usually performed
some what above 0.5Tm, furthermore, metal
continues to soften as temperature increases
above 0.5Tm, enhancing advantage of hot
working above this level.
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Advantage
• Work part shape can be significantly altered
• Lower forces and power required
• Metals that usually fracture in cold working can be hot formed.
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Limitation
• Lower dimensional accuracy
• Higher total energy required, which is the sum of
The thermal energy needed to heat the workpiece
Energy to deform the metal
• Work surface oxidation (scale)thus, poorer surface finish
• Shorter tool life.
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kindly follow the instructions below for next lecture’s
presentation on metal forming processes :
• All the members of the group should participate in the presentation.
• We need to split into four groups for our presentation.
• You may introduce the process .
• What are the advantages and disadvantages of this processes ?
• Application of process.
• You may share authentic example of process. (shall contain short
video)
• It is required for every group to do a total of 15-
minute presentations.
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Presentation titles :
• Rolling process.
• Drawing process.
• Extrusion process.
• Forging process.
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