Assignment: Chapter 3: Metal Forming and Shaping Processes

Assignment
CHAPTER 3 : METAL FORMING AND SHAPING

PROCESSES
1. What is metal forming?
 Metal forming is a large group of manufacturing processes in which plastic deformation is used to change
the shape of metal workpieces.
 The tool usually called a die, applies stresses that exceed the yield strength of the metal.
 The metal takes the shape determined by the geometry of the die.
 Material properties in metal forming are high ductility and low yield strength.
 These properties are affected by temperature where ductility increases and yield strength decreases when
work temperature is raised.
2. Describe briefly the stages during annealing
process
There are 3 stages of annealing process:

1. Recovery
2. Recrystallization
3. Grain Growth
Recovery
 Relieves the stresses from cold working

 Recovery involves annihaltion of point defects.
 Driving force for recovery decrease in stored energy from cold work.
 Physical properties of the cold worked materials are restored without any
observable change in microstructure.
 Recovery is first stage of annealing which takes place at low temperature of
annealing.
 There is some reduction, though not substantial, in dislocation density as well
apart from formation of dislocation configurations with low strain energies.
 The concentration of point defects decrease and dislocation is allowed to move to
lower energy positions without gross microstructional change.
Recrystallization
 This follows recovery during annealing of cold worked material. Driving force is
stored energy during cold work.
 It involves replacement of cold worked structure by a new set of strain free,
approximately equi-axed grains to replace all the deformed crystals.
 This process occurs above recrystallization temperature which is defined as the
temperature at which 50% of material recrystallizes in one hour,.
 The recrystallization is strongly dependent on the purity of a material.
Grain Growth
 Grain growth follows complete crystallization if the material is left

at elevated temperatures.
 Grain growth does not need to be preceded by recovery and
recrystallization, it may occur in all polycrystalline materials.
 Driving force for this process is reduction in grain boundary energy.
 Tendency for larger grains to grow at the expense of smaller grains
is based on physics.
3. Difference between bulk deformation and sheet metal
process
Differences Bulk Deformation Sheet Metal Process
Definition Metal forming operation in which Metal forming operation in which
significant change in shape occurs the geometry of a piece of sheet
via plastic deformation in metallic undergoes modification upon the
parts addition of a force
Work Piece Can be billet, rod, slab and more Only sheet metal
Area to volume Increases considerably No significant increase
ratio
Shape and cross Appreciable change in shape and Changes the shape significantly but
section cross section no change in cross section
Elastic Permanent plastic deformation is Permanent plastic deformation and
deformation higher than elastic deformation elastic deformation are
comparable.
Workpiece The area to volume ratio of The area to volume ratio of
workpiece is high workpiece is low
4. Select 3 components and discuss the criterias
1. Rice cooker pot (inner)

 The type of material used is aluminium disk
 The manufacturing process that takes place is blanking.
 Blanking is a metal fabricating process, during which a metal
workpiece is removed from yhe primary metal strip or sheet when it
is punched. The material that is removed is the new metal workpiece
or blank.
 Types of possible defects may occur are burrs fracture, burnishing,
rollover, and work hardening.
Advantages blanking process:
 Excellent dimensional control
 Good accuracy
 Repeatability through a production run
 Excellent part flatness is retained
 Straight and superior finishing edges to other metal stamping processes
The disadvantages are:

- slightly higher tooling cost when compared to traditional punching operations.
- slightly slower than traditional punching operations.
Three manufacturing companies of rice cooker:
 Grayns Malaysia Sdn. Bhd.

 Panasonic Manufacturing Malaysia
 Pensonic Holdings Berhad
2. Connecting Rod
 Type of material used is aluminium alloy
 Manufacturing process of involved is forging.

 Forging is a manufacturing process involving the shaping of metal using localized compressive
forces. The blows are delivered with a hammer or a die. Forging is often classified according to
the temperature at which it is performed: cold forging, warm forging, or hot forging.
 The possible defects in forging are exterior/interior cracking, folds, cold shuts, improper grain
flow and warping.
Advantages:
 Forging gives comparatively tougher product compare to casting.

 The fatigue strength and creep resistance of forge product is higher.
 Forge product has higher mechanical properties.
 Low cost operation.
 This process does not required special skill operator.
 Variety of shapes can be formed by this process.
Disadvantages:
 Higher initial cost for big forging presses.

 Secondary finishing process required in hot forging.
 It cannot produce complex shapes.
 Size is limited due to size of press.
 Brittle metal cannot be forged.
Three manufacturing companies of connecting rod:
 Top-end Industrial Manufacturing & Engineering Inc.

 Ningbo Haishu Yinlian Machinery Co., Ltd.
 ATI Industrial Co., Ltd.
3. Steel tube pipe
- Material used for steel tube pipes is stainless steel
 The manufacturing process for steel tube pipes is rolling
 In metalworking, rolling is a metal forming process in which metal stock is passed through one or
more pairs of rolls to reduce the thickness and to make the thickness uniform. The concept is
similar to the rolling of dough. Rolling is classified according to the temperature of the metal
rolled.
 The possible defects of rolling process are roll marks, dirt, rust and other cause related to prior
treatment and working of metal. The internal structural defects are wavy edges, zipper cracks at
the center of strip, edge cracks and alligatoring.
Advantages:
 High rate of production.
 Suitable for large reduction.
 Production of a wide range of shapes like blooms, billets, sheets, slabs, tubes, bars, structural
section, and others
Disadvantages:
 High cost of equipment.
 Poor finish and poor dimensional accuracy.
 Suitable for large sections’ production.
Three manufacturing companies for steel tube pipes
 Alpine Pipe Manufacturing Sdn. Bhd.

 Melewar Industrial Group Berhad
 Van Leeuwen Pipe & Tube Malaysia

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Assignment

CHAPTER 3 : METAL FORMING AND SHAPING

There are 3 stages of annealing process:

 Relieves the stresses from cold working

 Grain growth follows complete crystallization if the material is left

1. Rice cooker pot (inner)

The disadvantages are:

 Grayns Malaysia Sdn. Bhd.

 Type of material used is aluminium alloy

 Manufacturing process of involved is forging.

 Forging gives comparatively tougher product compare to casting.

 Higher initial cost for big forging presses.

 Top-end Industrial Manufacturing & Engineering Inc.

- Material used for steel tube pipes is stainless steel

 The manufacturing process for steel tube pipes is rolling

 Alpine Pipe Manufacturing Sdn. Bhd.

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