LO #2 Metal Froming Processes 201810

Manufacturing Technology 1
Metal Hot Rolling

Metal Forging
LO #2 Metal Forming Processes
LO #2 Metal Forming Processes
Topics
Identify bulk deformation process, hot working and cold
working of metals including:
Rolling: Types of rolling and defects in rolled parts.
Forging: Open-die, impression and closed-die forging and f

orging operations.
Drawing: Principle of rod and wire drawing, tube drawing
Extrusion: Principles and types of Extrusions.
Soldering
Shaping Operation – Deformation Process
 Deformation processes, in which the starting material is a ductile

solid (commonly metal) that is deformed to shape the part.
 In the deformation processes, the starting work part is shaped by

the application of forces that exceed the yield strength of the
material. For the material to be formed in this way, it must be
sufﬁciently ductile to avoid fracture during deformation. To
increase ductility (and for other reasons), the work material is
often heated before forming to a temperature below the melting
point. Deformation processes are associated most closely with
metalworking and include operations such as forging and
extrusion, shown in Figure 1.8. Figure 15.19 shows a forging
operation performed by a drop hammer.
Forging
Extrusion
 Also included within the deformation processes category is sheet

metalworking, which involves bending, forming, and shearing
operations performed on starting blanks and strips of sheet metal.
Several sheet metal parts, called stampings because they are
made on a stamping press, are illustrated in Figure 16.35.
Deformation Process : Hot and Cold Metal Working Process
1. Rolling
2. Forging
3. Extrusion
4. Drawing
5. Bending
Classification of Metal Forming
 Metal forming includes a large group of manufacturing
processes in which plastic deformation is used to
change the shape of metal work piece.
 Metal Forming classified into:
 Bulk Deformation.
 Sheet Metal working.
Reasons for metal forming:

The cast ingots produced by the raw material
producers are of little use for manufacturing
processes until they have been formed to a
suitable shape, i.e. sheet, plate, strip, bar
sections.
Basic Bulk Deformation
In these processes significant deformation and massive shapes

happened to the starting work piece, and its surface area-to-volume
ratio is small.
The starting work piece usually cylindrical billets or rectangular bars,
and the processes includes:
Rolling
In each case, (hot and cold rolling), the metal is worked while in a solid
state and is shaped by plastic deformation.
Working metals in its solid state will help to produce shapes which would
be difficult or expensive to produce by any other method, example: Long
length of sheet, sections, rod, etc., and to improve mechanical properties.
This is a compressive deformation process in which the thickness of a slab

or plate is reduced by two opposing cylindrical tools called rolls. The rolls
rotates so as to draw the work into the gap between them and squeeze it.
http://www.doitpoms.ac.uk/tlplib/metal-
forming-2/rolling.php
Rolling – Flat Rolling Process
Typical variation
Side view of flat rolling, indicating
in pressure
before and after thicknesses,
along the
work velocities, angle of contact
contact length in
with rolls, and other features.
flat rolling. The
peak pressure is
located at the
neutral point.
Rolling – Various configurations of rolling mills
Rolling – Steel Products
Hot Rolling advantages
 Most ingots when cast contain many small holes- a condition

known as porosity. During hot rolling, these holes are pressed
together and eliminated.
 Any impurities contained in the ingot are broken up and

dispersed throughout the metal.
 The internal grain structure of the metal is refined, resulting in

an improvement of the mechanical properties, e.g. ductility
and strength.
Hot Rolling Disadvantages
 Due to high temperatures, the surface oxidizes, producing a
scale which result in poor surface finish, making it difficult to
maintain dimensional accuracy.
 Where close dimensional accuracy and good surface finish are

not of great importance, e.g. structural shapes for construction
work, a descaling operation is carried out and the product is
used as-rolled. Alternately further work can be carried out by
cold rolling.
https://www.youtube.com/watch?v=AuuP8L-
WppI
Cold Rolling
https://www.youtube.com/watch?v=
YK2pvmVpoVM
 When metal is cold rolled, greater forces are required

,necessitating a large number of stages before reaching the
required shape. The strength of the material is greatly improved,
but this is accompanied by decrease in ductility.
 Depending upon number of stages required in producing the
shape, annealing may have to be carried out between stages.
 Cold rolling strengthens the metal and permits a tighter
tolerance on thickness. In addition, the surface of the cold-
rolled sheet is absent of scale and generally superior to the
corresponding hot-rolled product
Forging Process https://www.youtube.com/watch?v=mRA6RY2
o9Lg
Forging: In forging a work piece is compressed between two

opposing dies, so that the die shapes are imparted to the work.
Forging is traditionally a hot working process, but many types of
forging are performed cold.
Forging Process
The oldest form of forging is Hand forging as carried out by the black
smith. Hand tools are used to manipulate the hot metal to give changes in
section and changes in shape by bending, twisting, etc.
Due to hand operation, it is not possible to achieve high degree of

accuracy or extreme complexity of shape.
This method is limited to one -off or small quantities and requires a high
degree of skill.
When forging is large, some form of power is employed. Steam or

compressed air hammers or a forging press is used , the process is know
as Open-sided forging.
This method is used to produce large forgings such as propeller shaft for
ships.
When large quantities of accurately shaped product are required, these

are produces by a process known as closed-die forging or Drop forging.
Forging Application
Forging is used in the production of parts which have to withstand
heavy or unpredictable loads, such as levers, cams, gears, connecting
rods and axel shafts and spanners.
Mechanical properties are improved by forging due to controlled grain
flow.
For Example: A spanner cut from the rolled sheet would be much
weaker compared to one produced from forging.
Forging Comparison
The advantages of forging, compared to machining the part completely,
are higher production rates, conservation of metal, greater strength, and
favorable grain orientation of the metal that results from forging.
Forging Details
 Forging is carried out in many different ways. One way to classify the
operations is by working temperature. Most forging operations are
performed hot or warm, owing to the significant deformation demanded by
the process and the need to reduce strength and increase ductility of the
work metal. However, cold forging is also very common for certain
products. The advantage of cold forging is the increased strength that
results from strain hardening of the component.
 Either impact or gradual pressure is used in forging. The distinction derives

more from the type of equipment used than differences in process
technology. A forging machine that applies an impact load is called a
forging hammer, while one that applies gradual pressure is called a
forging press.
Forging Details
 Another difference among forging operations is the degree to which the flow
of the work metal is constrained by the dies. By this classification, there
are three types of forging operations.
(a)Open-die forging,
(b)Impression- die forging
(c)Flashless forging.
Forging Details
In open-die forging, the work is compressed between two flat (or almost flat) dies, thus
allowing the metal to flow without constraint in a lateral direction relative to the die surfaces.
Forging Details
In impression-die forging, the die surfaces contain a shape or impression that is

imparted to the work during compression, thus constraining metal flow to a
significant degree. In this type of operation, a portion of the work metal flows
beyond the die impression to form flash, as shown in the figure. Flash is excess
metal that must be trimmed off later.
Forging Details
In flashless forging, the work is completely constrained within

the die and no excess flash is produced. The volume of the
starting workpiece must be controlled very closely so that it
matches the volume of the die cavity.
Forging Details
Coining is a special application of closed-die forging in

which fine details in the die are impressed into the top and
bottom surfaces of the work part.
Forging Details – Analysis of Open – Die Forging
Problem – an example
EXTRUSION PROCESS
Extrusion: similar to plastics extrusion process, but here a

compression process used in which the work metal is forced
to flow though a die opening. Thereby taking the shape of
the opening as its own cross section.
https://www.youtube.com/watch?v=iiGl
q7408ME
EXTRUSION PROCESS
 The extrusion produced has a constant cross section along its entire
length.
 The die may contain a number of openings, simultaneously producing
a number of extrusions.
 There are number of variations of extrusion process, the two most
common methods are
 Direct extrusion and indirect extrusion.
Products examples:
EXTRUSION PROCESS
 Direct Extrusion ( = Forward extrusion): A metal billet is loaded into a
container, and a ram compressed the material, forcing it to flow
through one or more openings in a die at the opposite end of the
container.
https://www.youtube.co
m/watch?v=iiGlq7408
ME
Hollow sections
Semi-hollow
sections
EXTRUSION PROCESS
 Indirect Extrusion ( = backward / reverse extrusion): The die is mounted to
the ram rather than at the opposite end of the container. As the ram
penetrates into the work, the metal is forced to flow through the clearance
in a direction opposite to the motion of the ram.
Hollow cross section

Solid cross sections
 Practical Limitations :
- Length of the extruded part, and support of the ram as work length increases.
Important Features of the extrusion process
 The complexity of the shape possible is practically unlimited,

and finished products can be produced directly.
 A good surface finish can be maintained.
 Good dimensional accuracy can be obtained.
 Large reduction in cross sectional area can be achieved.
 Since the metal is in compression during the process, so

relatively brittle materials can be extruded.
 The mechanical properties of the material are improved.
Extrusion Limitation
 The extrusion process is however, limited to products which

have a constant cross section. Any slots, holes etc. not
parallel to the longitudinal axis have to be machined.
 Due to extrusion-press power capabilities, the size of shape

which can produced is limited.
 The process is normally limited to long runs, due to die

costs, but short runs can be economical with simple die
shapes.
 Typical materials used are copper and aluminum alloys.
Hot versus Cold Extrusion
Extrusion can be performed either hot or cold, depending on work metal and
amount of strain to which it is subjected during deformation. Metals that are
typically extruded hot include aluminum, copper, magnesium, zinc, tin, and
their alloys. These same metals are sometimes extruded cold. Steel alloys
are usually extruded hot, although the softer, more ductile grades are
sometimes cold extruded (e.g., low carbon steels and stainless steel).
Aluminum is probably the most ideal metal for extrusion (hot and cold) and
many commercial aluminum products are made by this process (structural
shapes, door and window frames, etc.).
Cold extrusion and warm extrusion are generally used to produce discrete
parts, often in finished (or near finished) form. The term impact extrusion
is used to indicate high-speed cold extrusion. Some important advantages
of cold extrusion include increased strength due to strain hardening,
close tolerances, improved surface finish, absence of oxide layers, and
high production rates. Cold extrusion at room temperature also eliminates
the need for heating the starting billet.
Hot versus Cold Extrusion
Hot extrusion involves prior heating of the billet to a temperature above its
recrystallization temperature. This reduces strength and increases ductility
of the metal, permitting more extreme size reductions and more complex
shapes to be achieved in the process.
Additional advantages include reduction of ram force, increased ram

speed, and reduction of grain flow characteristics in the final product.
Cooling of the billet as it contacts the container walls is a problem, and

isothermal extrusion is sometimes used to overcome this problem.
Lubrication is critical in hot extrusion for certain metals (e.g., steels), and
special lubricants have been developed that are effective under the harsh
conditions in hot extrusion. Glass is sometimes used as a lubricant in hot
extrusion; in addition to reducing friction, it also provides effective thermal
insulation between the billet and the extrusion container.
Wire and Bar Drawing Process
https://www.youtube.com/watch?v=wlWkz9
hjASo
Drawing :The process of drawing is a cold working process, i.e.

carried out at room temperature. It is mainly used in the production
of wires, rods and bar.
Drawing
Process
 In continuous wire drawing , the wire is pulled through the series of

progressively smaller dies until the final-size section is reached.
 The strength of the material will limit the force which can be applied in
pulling the wire through the die, while the ductility of the material limits
the amount of reduction possible through each die.
 Typical materials used are steel, copper, aluminum and their alloys.
Tube Drawing
Drawing can be used to reduce the diameter or
wall thickness of seamless tubes and pipes,
after the initial tubing has been produced by
some other process such as extrusion. Tube
drawing can be carried out either with or without
a mandrel. The simplest method uses no
mandrel and is used for diameter reduction.
The term tube sinking is sometimes applied to
this operation.
Tube Drawing
The problem with tube drawing in which no mandrel is used is that

it lacks control over the inside diameter and wall thickness of the
tube. This is why mandrels of various types are used
The first, shown in(a),uses a fixed mandrel attached to a long support

bar to establish inside diameter and wall thickness during the
operation. Practical limitations on the length of the support bar in this
method restrict the length of the tube that can be drawn.
The second type, shown in (b), uses a floating plug whose shape is
designed so that it finds a ‘‘natural’’ position in the reduction zone of
the die. This method removes the limitations on work length present
with the fixed mandrel.
Selection of manufacturing process
 A number of factors have to be considered before a choice of

process for a given component can be made.
 For example: consideration would have to be given to the type

of material used, the mechanical properties required, shape,
accuracy, degree of surface finish and the quantity to be
produced.
 Table on the next slide gives the idea.
Comparison of different processes

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Manufacturing Technology 1

Metal Hot Rolling

LO #2 Metal Forming Processes

Rolling: Types of rolling and defects in rolled parts.

Forging: Open-die, impression and closed-die forging and f

Drawing: Principle of rod and wire drawing, tube drawing

Extrusion: Principles and types of Extrusions.

 Deformation processes, in which the starting material is a ductile

 In the deformation processes, the starting work part is shaped by

 Also included within the deformation processes category is sheet

Reasons for metal forming:

In these processes significant deformation and massive shapes

This is a compressive deformation process in which the thickness of a slab

 Most ingots when cast contain many small holes- a condition

 Any impurities contained in the ingot are broken up and

 The internal grain structure of the metal is refined, resulting in

 Where close dimensional accuracy and good surface finish are

 When metal is cold rolled, greater forces are required

Forging: In forging a work piece is compressed between two

Due to hand operation, it is not possible to achieve high degree of

When forging is large, some form of power is employed. Steam or

When large quantities of accurately shaped product are required, these

 Either impact or gradual pressure is used in forging. The distinction derives

In impression-die forging, the die surfaces contain a shape or impression that is

In flashless forging, the work is completely constrained within

Coining is a special application of closed-die forging in

Extrusion: similar to plastics extrusion process, but here a

Hollow cross section

 The complexity of the shape possible is practically unlimited,

 A good surface finish can be maintained.

 Good dimensional accuracy can be obtained.

 Large reduction in cross sectional area can be achieved.

 Since the metal is in compression during the process, so

 The mechanical properties of the material are improved.

 The extrusion process is however, limited to products which

 Due to extrusion-press power capabilities, the size of shape

 The process is normally limited to long runs, due to die

 Typical materials used are copper and aluminum alloys.

Additional advantages include reduction of ram force, increased ram

Cooling of the billet as it contacts the container walls is a problem, and

Drawing :The process of drawing is a cold working process, i.e.

 In continuous wire drawing , the wire is pulled through the series of

The problem with tube drawing in which no mandrel is used is that

The first, shown in(a),uses a fixed mandrel attached to a long support

 A number of factors have to be considered before a choice of

 For example: consideration would have to be given to the type

 Table on the next slide gives the idea.

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