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Metal Forming Process
Metal Forming Process
What is Manufacturing?
The word manufacture is derived from two Latin
words manus (hand) and factus (make); the
combination means “made by hand”
It encompasses (1) Design of the product (2)
selection of raw materials (3) Sequence of
processes
Most modern manufacturing operations are
accomplished by mechanized and automated
equipment that is supervised by human workers
Basic Manufacturing Processes
– Casting (Melting and Pouring in to cavity of desired
shape and size)
– Metal Forming and shaping (Plastic Deformation
Process- Rolling, Forging, Extrusion, Drawing, Sheet
Forming)
– Machining (Removing the excess materials by relative
movement between cutting tool and work piece
material- Turning, Boring, Milling, Planing, Broaching)
– Joining (Assembling different parts or components-
welding, brazing , soldering )
– Finishing (Honing, Lapping, Polishing, burnishing,
deburring, coating and plating)
Manufacturing Processes: Casting
Drawing Shearing
Extrusion
Schematic
illustration of the
effects of
recovery,
recrystallization,
and grain growth
on mechanical
properties and on
the shape and size
of grains. Note
the formation of
small new grains
during
recrystallization.
Hot Working and Cold Working
Cold Working:
Performed at room temperature or slightly above
Many cold forming processes are important mass production operations
Minimum or no machining usually required
These operations are near net shape or net shape processes
Advantages of Cold Forming vs. Hot Working:
Better accuracy, closer tolerances
Better surface finish
Strain hardening increases strength and hardness
Grain flow during deformation can cause desirable directional properties in
product
No heating of work required (less total energy)
Disadvantages of Cold Forming:
Equipment of higher forces and power required
Surfaces of starting work piece must be free of scale and dirt
Ductility and strain hardening limit the amount of forming that can be done
Hot Working and Cold Working
Hot Working:
o Deformation at temperatures above recrystallization temperature.
o In practice, hot working usually performed somewhat above 0.5Tm.
o Metal continues to soften as temperature increases above 0.5Tm,
enhancing advantage of hot working above this level.
Advantages of Hot Working vs. Cold Working
Work part shape can be significantly altered
Lower forces and power required (equipment)
Metals that usually fracture in cold working can be hot formed
Strength properties of product are generally isotropic
No strengthening of part occurs from work hardening
Disadvantages of Hot Working:
Lower dimensional accuracy
Higher total energy required
Warm Working
Warm Working:
Performed at temperatures above room temperature but below
recrystallization temperature
Advantages of Warm Working:
Lower forces and power than in cold working
More intricate work geometries possible
Need for annealing may be reduced or eliminated
Warm working: T/Tm from 0.3 to 0.5