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    Metal Forming 1

    Uploaded by

    Álvaro Arango
    The document discusses metal forming processes used in manufacturing. It describes forming as changing the shape of a solid body using plastic deformation, while shaping involves molding and casting. The main metal forming techniques covered are sheet metal working processes like bending and drawing, and bulk deformation processes like rolling, forging, extrusion, and drawing. Examples are provided of precision cold forged and hot forged complex metal shapes. Metal forming is important for manufacturing due to benefits like net or near-net shape production, high production rates, lower scrap rates, and improved material properties.

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    Attribution Non-Commercial (BY-NC)
    Download as PPS, PDF, TXT or read online from Scribd

    Metal Forming 1

    Uploaded by

    Álvaro Arango
    220 views23 pages
    The document discusses metal forming processes used in manufacturing. It describes forming as changing the shape of a solid body using plastic deformation, while shaping involves molding and casting. The main metal forming techniques covered are sheet metal working processes like bending and drawing, and bulk deformation processes like rolling, forging, extrusion, and drawing. Examples are provided of precision cold forged and hot forged complex metal shapes. Metal forming is important for manufacturing due to benefits like net or near-net shape production, high production rates, lower scrap rates, and improved material properties.

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    The document discusses metal forming processes used in manufacturing. It describes forming as changing the shape of a solid body using plastic deformation, while shaping involves molding and casting. The main metal forming techniques covered are sheet metal working processes like bending and drawing, and bulk deformation processes like rolling, forging, extrusion, and drawing. Examples are provided of precision cold forged and hot forged complex metal shapes. Metal forming is important for manufacturing due to benefits like net or near-net shape production, high production rates, lower scrap rates, and improved material properties.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPS, PDF, TXT or read online from Scribd
    Download as pps, pdf, or txt
    220 views23 pages

    Metal Forming 1

    Uploaded by

    Álvaro Arango
    The document discusses metal forming processes used in manufacturing. It describes forming as changing the shape of a solid body using plastic deformation, while shaping involves molding and casting. The main metal forming techniques covered are sheet metal working processes like bending and drawing, and bulk deformation processes like rolling, forging, extrusion, and drawing. Examples are provided of precision cold forged and hot forged complex metal shapes. Metal forming is important for manufacturing due to benefits like net or near-net shape production, high production rates, lower scrap rates, and improved material properties.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPS, PDF, TXT or read online from Scribd
    Download as pps, pdf, or txt
    of 23
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    The document discusses various metal forming processes including bulk deformation processes like rolling, forging, extrusion and drawing as well as sheet metalworking processes like bending, drawing and shearing. It also discusses applications, skills required and current issues in metal forming industry.

    Some examples of bulk deformation processes discussed are rolling, forging, extrusion and drawing.

    Some examples of sheet metalworking processes discussed are bending, drawing and shearing.

    Fundamentals of Metal Forming Processes

    Amr Shehata Fayed, Ph.D.


    Assistant Professor of Mechanical Engineering Materials Engineering Department Faculty of Engineering Zagazig University

    Dr. Amr Shehata Fayed

    Forming and Shaping

    Forming: means changing the shape of an existing solid body. Ex. The metal body for a car (sheet metal forming)

    Shaping: usually involves molding and casting. Ex. The white ceramic insulator for a spark plug of a car body for a car (clay molding, drying and firing)

    Dr. Amr Shehata Fayed

    Metal Forming Processes

    Metal Forming includes a large group of manufacturing processes in which plastic deformation is used to change the shape of metal work-pieces. Deformation results from the use of a tool, usually a die in metal forming, which applies stresses that exceed the yield strength of the metal.
    3

    Dr. Amr Shehata Fayed

    (a) (b) (c)

    (d)

    (e)

    (f)

    (g)

    (h)

    Hammer forging two connecting rods; (a) bar stock; after (b) fullering, (c) rolling, (d) blocking, (e) finishing, (f) trimming; (g) the flash; (h) the forging dies.
    Dr. Amr Shehata Fayed 4

    Metal Forming Processes


    Sheet Metal-working:
    Also called Press-working. Cold working processes. Use set of punch and die.

    Bulk Deformation:
    Compressive deformation force. Significant deformations. Massive shape changes.

    Performed on metal sheets,


    strips and coils. Surface area / volume is large.
    Dr. Amr Shehata Fayed 5

    Starting work shapes include


    billets and rectangular bars.

    Surface area / volume is small.

    Metal Forming Processes


    Sheet Metalworking Bending operations Shearing processes Deep or Cup drawing
    Dr. Amr Shehata Fayed 6

    Bulk Deformation
    Surface Area / Volume is small

    Surface Area / Volume is large

    Rolling Forging Extrusion

    Wire and Bar drawing

    Bulk Deformation Processes


    Rolling: A compressive deformation process in
    which the thickness of slab or plate is reduced by two opposing tools rolls. They rotate to draw the work piece into the gap between them and squeeze it.

    Dr. Amr Shehata Fayed

    Bulk Deformation Processes


    Forging: The work-piece is compressed between two
    opposing dies so that the die shapes are imparted to work. It is traditionally hot working process however many types of forging are performed cold.

    Dr. Amr Shehata Fayed

    Bulk Deformation Processes


    Extrusion: A compressive deformation process in
    which the work metal is forced to flow through a die opening to produce a desired cross-sectional shape.

    Dr. Amr Shehata Fayed

    Bulk Deformation Processes


    Drawing: The work metal is being pulled through a
    die opening to reduce the diameter of a wire or a bar. See Fig. Wire Drawing.

    Dr. Amr Shehata Fayed

    10

    Examples of Precision Cold Forged Products

    Dr. Amr Shehata Fayed

    11

    Precision Hot Forging of Complex Shapes

    Dr. Amr Shehata Fayed

    12

    Precision Hot Forging of Complex Shapes

    Dr. Amr Shehata Fayed

    13

    Sheet Metalworking Processes


    Bending: It involves straining of metal sheet or plate
    to take an angle along a (usually) straight axis.

    Dr. Amr Shehata Fayed

    14

    Sheet Metalworking Processes


    Drawing: (Cup or deep drawing) Forming of a flat
    metal sheet into a hollow or concave shape, such as cup, by stretching the metal. A blank holder is used to hold down the blank while the punch pushes into the sheet metal.

    Dr. Amr Shehata Fayed

    15

    Dr. Amr Shehata Fayed

    16

    Sheet Metalworking Processes


    Shearing: It involves cutting rather than forming of
    a metal. A shearing operation cuts the work using a punch and die.

    Dr. Amr Shehata Fayed

    17

    Importance of Metal Forming in Manufacturing Engineering


    Net Shape or Close to Net Shape High Production Rate High Profit Margin Low Scrap Rate Improving Material Properties

    Dr. Amr Shehata Fayed

    18

    Applications and Products of Metal forming in Macro Scale


    Automotive Aerospace Appliance Cookware

    Dr. Amr Shehata Fayed

    19

    Current Issues of Metal Forming Industry


    Lack of Experienced Metal Forming Engineer Short Product Life Cycle New Metallic Materials Developing New Hybrid Process High Accuracy and Small Feature Products

    Dr. Amr Shehata Fayed

    20

    Skills Needed for Metal Forming Engineering


    Mechanics Material Science Manufacturing Process Design and Control Machinery Computer Skills FEA
    21

    Dr. Amr Shehata Fayed

    Students Need
    To know the current and future needs of metal forming industry. To be taught on a series of classes to meet challenges of current and future metal forming industry.

    Dr. Amr Shehata Fayed

    22

    Homework
    Is metal forming the most cost effective manufacturing process? Why metal forming is the best process for mass production? According to your imagination, what is the best process to make beverage can?

    Dr. Amr Shehata Fayed

    23

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