Thapar Institute of Engineering & Technology – Patiala
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Manufacturing Processes
UES102
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Manufacturing Processes
UES102
Introduction to Metal Forming
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METAL FORMING
Metal forming includes a large group of manufacturing
processes in which plastic deformation is used to change
the shape of metal workpieces.
Deformation results from the use of a tool, usually called a
die in metal forming, which applies stresses that exceed
the yield strength of the metal.
The metal therefore deforms to take a shape determined
by the geometry of the die.
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METAL FORMING
Stresses applied to plastically deform the metal are
usually compressive.
However, some forming processes stretch the metal, while
others bend the metal, and still others apply shear
stresses to the metal.
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METAL FORMING
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METAL FORMING
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Remembering stress strain diagram
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PUNCH AND DIE
PUNC
H
DIE
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METAL
FORMING
PUNC
H
DIE
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METAL
FORMING
PUNC
H
DIE
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METAL
FORMING
PUNC
H
DIE
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METAL
FORMING
PUNC
H
DIE
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METAL
FORMING
PUNC
H
DIE
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METAL
FORMING
PUNC
H
DIE
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METAL
FORMING
Since the material is simply moved (or rearranged) to
produce the shape, as opposed to cutting away unwanted
regions, the amount of waste can be substantially reduced.
Unfortunately, the forces required are often high.
Machinery and tooling can be quite expensive for metal
forming operations.
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METAL
FORMING
To be successfully formed, a metal must possess certain
properties.
Desirable properties include
low yield strength and
high ductility.
These properties are affected by temperature.
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EFFECT OF TEMPERATURE
In metalworking operations, workpiece temperature can
be one of the most important process variables.
In general, an increase in temperature brings about a
decrease in strength, an increase in ductility, and a
decrease in the rate of strain hardening—all effects
that would tend to promote ease of deformation.
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EFFECT OF TEMPERATURE
Forming processes tend to be classified as
Cold Working
Warm Working
Hot Working
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COLD WORKING
The plastic deformation of metals below the
recrystallization temperature is known as cold
working .
Here, the deformation is usually performed at room
temperature, but mildly elevated temperatures may be
used to provide increased ductility and reduced strength.
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COLD WORKING ADVANTAGES
1. No heating is required.
2. Better surface finish is obtained.
3. Superior dimensional control is achieved since the
tooling sets dimensions at room temperature.
4. Products possess better reproducibility and
interchangeability.
5. Strength, fatigue, and wear properties are all improved
through strain hardening.
6. Contamination problems are minimized
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COLD WORKING DISADVANTAGES
1. Higher forces are required to initiate and complete the
deformation.
2. Heavier and more powerful equipment and stronger tooling
are required.
3. Less ductility is available.
4. Metal surfaces must be clean and scale-free.
5. Intermediate anneals(heating) may be required to compensate
for the loss of ductility that accompanies strain hardening.
6. Undesirable residual stresses may be produced.
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WARM WORKING
Because plastic deformation properties are normally enhanced
by increasing workpiece temperature, forming operations are
sometimes performed at temperatures somewhat above room
temperature BUT below the recrystallization temperature.
The term warm working is applied to this second temperature
range.
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WARM WORKING
The dividing line between cold working and warm working is
often expressed in terms of the melting point for the metal.
The dividing line is usually taken to be 0.3 Tm
Tm = is the melting point (absolute temperature) for the
particular metal.
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WARM WORKING
The lower strength and strain hardening at the intermediate
temperatures, as well as higher ductility, provide warm
working with the following advantages over cold working:
1. lower forces and power,
2. more intricate work geometries possible,
3. need for annealing may be reduced or eliminated
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HOT WORKING
Hot working (also called hot forming) involves deformation
at temperatures above the recrystallization temperature.
The recrystallization temperature for a given metal is about
one-half of its melting point on the absolute scale (Kelvin
or Rankine).
In practice, hot working is usually carried out at
temperatures somewhat above 0.5 Tm .
In some books it has been given above 0.6 Tm .
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HOT WORKING
Scale (a coating of oxide formed on heated metal) on the
work surface is accelerated at higher temperatures.
Accordingly, hot working temperatures are usually
maintained with in the range 0.5 Tm to 0.75 Tm .
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HOT WORKING ADVANTAGES
1. The shape of the workpart can be significantly altered
2. Lower forces and power are required to deform the metal
3. Metals that usually fracture in cold working can be hot
formed
4. No strengthening of the part occurs from work hardening.
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HOT WORKING DISADVANTAGES
1. Lower dimensional accuracy
2. Higher total energy required (due to the thermal energy to
heat the workpiece),
3. Work surface oxidation (scale),
4. Poorer surface finish, and
5. Shorter tool life.
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References:
M.P. Groover, Fundamentals Of Modern Manufacturing:
Materials, Processes, and Systems, Wiley (2016), 5th
edition.
Degarmo, E. P., Kohser, Ronald A. and Black, J. T.,
Materials and Processes in Manufacturing, Prentice Hall
of India (2008) 8th ed.
Kalpakjian,S. and Schmid, S. R., Manufacturing
Processes for Engineering Materials, Dorling Kingsley
(2006) 4th ed.
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