QUESTION 1

INTRODUCTION TO METAL FORMING

Metal forming is a manufacturing process where a metal workpiece is shaped into a desired form by
applying compressive forces, utilizing its plastic deformation properties to create parts without removing
material, making it a crucial technique for producing complex metal components with high precision and
efficiency across various industries; key metal forming processes include rolling, extrusion, forging,
bending, and stamping.

IMPORTANCE IN MANUFACTURING

The ability to create intricate geometries, use a variety of materials, and achieve high production volumes
with automation are just a few of the ways that metal forming is essential to manufacturing because it
makes it possible to create complex, precise metal shapes with little waste of material. This makes it a
flexible and economical way to produce high-quality components for a variety of industries, often with
enhanced strength and durability due to the plastic deformation of the metal during the forming process.

BASIC PRINCIPLES OF PLASTIC DEORMATION:

STRESS:

In a metal forming process, stress plays a crucial role as it is the force applied to a metal
workpiece that causes it to deform plastically, allowing the material to be shaped into a desired form by
exceeding its yield strength, essentially enabling the entire metal forming process to occur

Stress is defined as the intensity of force, F, at a point.

σ = ∂F/∂ A
as
∂ A → 0,

where A is the area on which the force acts.

If the stress is the same everywhere,
σ = F/A.

There are nine components of stress . A normal stress component

is one in which the force is acting normal to the plane. It may be tensile or compressive.
A shear stress component is one in which the force acts parallel to the plane.
Stress components are defined with two subscripts. The first denotes the normal
to the plane on which the force acts and the second is the direction of the force.∗ For
example, σx x is a tensile stress in the x-direction. A shear stress acting on the x-plane
in the y-direction is denoted σx y .
. Nine components of stress acting on an
infinitesimal element.

STRAIN:

In metal forming, "strain" represents the amount of deformation a metal undergoes during
the process, and plays a critical role as it directly influences the material's strength and resistance
to further deformation

ROLE OF STRESS AND STRAIN:

An understanding of stress and strain is essential for analyzing metal forming oper
ations. Often the words stress and strain are used synonymously by the nonscientific
public.

 In metal forming, we apply stress (force) to change the shape of a metal piece.
 If the force is small, the metal bends but returns to its original shape (elastic deformation).
 If the force is large enough, the metal permanently changes shape (plastic deformation).

TYPES OF METAL FORMING PROCESS

FORGING:

Forging is the working of metal into a useful shape by hammering or pressing. The oldest of the
metalworking arts (primitive blacksmith). Forging machines are now capable of making parts ranging in
size of a bolt to a turbine rotor. Most forging operations are carried out hot, although certain metals
may be cold-forged.

Products Made:

 Automotive components (crankshafts, gears, connecting rods)

 Aerospace parts (landing gear, turbine blades)
 Hand tools (wrenches, hammers)
 Medical implants
 Rail components

Typical Materials:

 Carbon steel
 Alloy steel
 Stainless steel
 Titanium
  Aluminum
 Copper and its alloys (bronze, brass)

It is classified into two:

ROLLING:

The rolling process is a metalworking technique that involves passing a material through a
gap between two or more rotating rollers. The rollers deform the material by compressing
and stretching it. This process is used to create sheets, rods, tubes, and other structural
sections.

Products Made:

 Sheet metal
 Structural steel (I-beams, rails, plates)
 Automotive body panels
 Roofing sheets
 Pipes and tubes

Typical Materials:

 Mild steel
 Stainless steel
 Aluminum
 Copper
 Brass
EXTRUSION:
In extrusion, a molten polymer is forced under pressure through a die to define a constant
cross-sectional shape or profile after the exiting polymer is solidified, typically by cooling.
Extrusion is used to make simple profiles such as flat sheets, rods and tubes, and more
complicated profiles, such as honeycombs.

Products Made:

 Aluminum window frames

 Pipes and tubing
 Electrical wiring and conduits
 Automotive trim and body parts
 Plastic profiles (PVC pipes, door frames)

Typical Materials:

 Aluminum
 Copper
 Brass
 Magnesium
 Lead
 Plastics (PVC, polyethylene)
DRAWING:
Drawing is a metal forming process (cold working process). In this process rod or tube is pulled through
a tapered hole in a die which results in reduction in cross section area. The shape of die determines the
final product shape. Quality of product obtained is excellent. This process increases strength and
hardness of the metal.

Products Made:

 Wires (electrical wires, cables)

 Tubes (hypodermic needles, bicycle frames)
 Rods for construction
 Metal threads for fasteners

Typical Materials:

 Copper
 Aluminum
 Stainless steel
 Carbon steel
 Brass
SHEET METAL FORMING:

Sheet metal forming is a manufacturing process where thin metal sheets are plastically deformed
into desired shapes without altering their thickness significantly

Products Made:

 Automobile body panels

 Aircraft fuselage and wings
 Electrical enclosures
 Kitchen appliances (refrigerator panels, washing machine bodies)
 Roofing sheets

Typical Materials:

 Mild steel
 Stainless steel
 Aluminum
 Copper
 Brass

The major sheet metal forming processes include:

1. Bending

Bending is a process in which a sheet is subjected to a force that causes it to bend at an angle
along a straight axis.
Products Made:

 Sheet metal brackets

 Automotive chassis components
 HVAC ductwork
 Enclosures and cabinets
 Aircraft components

Typical Materials:

 Mild steel
 Stainless steel
 Aluminum
 Copper

2. Stretching

Stretching involves applying tensile forces to the sheet to increase its surface area while reducing
thickness in certain regions.

Products Made:

 Automotive hoods and doors

 Aircraft skin panels
 Cooking utensils (pans, trays)
 Decorative metal panels

Typical Materials:

 Aluminum
 Stainless steel
 Titanium
  Copper

DEEP DRAWING:

Deep drawing is a metalworking process that involves mechanically pulling a sheet of metal into a die to
form a complex shape. It's used to create intricate components and designs.

Products Made:

 Beverage cans
 Kitchen sinks
 Automotive fuel tanks
 Fire extinguishers
 Cooking pots

Typical Materials:

 Low-carbon steel
 Stainless steel
 Aluminum
 Copper