A complex geometry

A given material (shape, size, accuracy,

(shapeless or a simple geometry) tolerances, appearance,
Properties)

Primary shaping processes Casting, melt extrusion, die casting, etc.

Metal forming processes Rolling, extrusion, forging, bending, drawing

(plastic deformation)

Metal cutting processes Sawing, turning, milling

(by removing metal)
Heat treatment, surface hardening
Metal treatment processes (unchanged in shape, changed in properties)
Metallurgical joining : welding,
Joining processes
Mechanical joining : riveting, shrink fitting, assembly
 Massive forming processes (Bulk forming processes)
: forging, extrusion, rolling, drawing
Material type •Large plastic deformation, appreciable change in shape or cross section,
•The portion of permanent deformation >> elastic deformation
•Elastic deformation is negligible
Sheet forming processes
: deep drawing, stretch forming, press forming
•Sheet, changes in shape, not in section, permanent=elastic, e/recovery
Cold forming processes : room temperature
Forming temp.
Hot forming processes : above the recrystallization temp.
☞ Most materials behave differently under different temperature condition
; [cold forming] Y.S. increases with an increase of strain
; [hot forming ] Y.S. increases with an increase of strain rate

Attractive points
☞ in case where the part geometry is of moderate complexity
☞ in case where the production volume are large
☞ in case where tooling costs per unit product should be kept low
Closed die forging with flash
☞ a billet is formed (usually hot) in dies (usually with two halves)
☞ the excess of the material is extruded through a restrictive narrow gap
Closed die forging without flash
☞ in this process, a billet with carefully controlled is deformed by a punch
☞ in order to fill a die cavity without any loss of material, the punch and
the die may be made of one or several pieces
Coining process
☞ coining is a closed die forging (usually called restriking)
☞ all surfaces of the work are confined or restricted
☞ resulting in well-defined imprint of the die on the workpiece
Coining process
☞ Open die forging is a hot forming process
☞ the metal is shaped by hammering or pressing between flat or simple
contoured dies.
☞ most of shafts can be manufactured by this process
☞ Open die forging is a hot forming process
☞ the metal is shaped by hammering or pressing between flat or simple
contoured dies.
☞ most of shafts can be manufactured by this process
☞ orbital forging shapes parts by incrementally forging a slug between
an rotating upper die and a non-rotating lower die
☞ the lower die is raised axially toward the upper die, which is fixed axially
Fi gure 5. Comparison bet w een class i cal a n d orbi tal f orgi ng
w i t h d i f f e re n t a x l e ro t a t i o n a n g l e s (n u m e r i c a l a n a l y s i s )
☞ Through the upsetting process, the cross sectional area in increased (heading)
☞ A punch compresses a billet (hot or cold) confined in a container
☞ the billet material flows through a die in the same direction as the punch
☞ a moving punch applies a steady pressure to a slug confined in a closed die
☞ it forces the metal to flow around the punch in a direction
opposite the punch direction
☞ a hot or cold forming process for reducing the cross-sectional area
☞ this process uses rotating rolls
☞ the rolled material (plate) elongates and spreads at the same time
☞ Shape rolling is a cold or hot forming process for reducing as well as
shaping the cross section of the metal
☞ the metal passes through a series of rotating sets of rolls with grooves
☞ the process of reducing the cross section and the diameter of a tube
☞ a process where a hollow circular blank is formed into a ring
☞ a main roll presses on the outside diameter of the blank
☞ shaped cross section is obtained by contouring of the mandrel and the roll
☞ a process for hot or cold seamless shaping of dished part
☞ it uses the combined forces of rotating and pressure
☞ drawing is the process of reducing the cross-sectional area and the shape
of a rod, bar, tube or wire by pulling through a die
☞ a sheet blank is forced by a punch into a die to form a deep recessed part
☞ this process is used to produce cylindrical cup shape
☞ an internal pressure is applied so as to form a tube to the desired shape
☞ the internal pressure can be delivered by expanding a punch through
a fluid
☞ roll bending gives a curvature to a sheet, bar or shaped section by bending it
between two or three cylindrical rolls
Cold stamping Tailor welded blank

Roll forming Hot stamping

1. 다음 사진의 제품을 제조하기 위해 어떤 공정으로 성형할지 설명하시오. (각 5점)

(1) CNG (Compressed Natural Gas) 압력용기 (2) 풍력발전기 타워플랜지

(3) 자동차 알루미늄 서스펜션 암 (4) 금속재 파이프

Selection of a Metal Forming Process ?
Preparation of Material ?
Tool Design ?
Machine or Equipment ?
 Flow stress as a function of strain, strain rate, temperature,
Billet material microstructure (constitutive equation)
Workability as a function of strain, strain rate, etc
(forming limit diagram)
Surface condition
Mechanical properties (thermal/physical)

Geometry of tools
Tooling
 

Surface condition
  f   ,  , T 
Heat treatment / hardness  
Accuracy / tolerances
Lubricant type and condition
  P  mk
Interfacial
condition Cooling characteristics of the interface layer 
k
Friction 3