Lecture 7

Metal Forming Processes

 Rolling
 Forging
 Extrusion
Wire Drawing
 Deep Drawing

Manufacturing Processes - ME 205 Forming - 1

 Classification of Metal Fabrication Techniques

Manufacturing Techniques

Special Processes Welding Forming Casting

Machining
‫اللحام الغازي‬ Rolling ‫الدرفلة‬ ‫السباكة الرملية‬
Turning ‫الخراطة‬
Gas Welding Sand Casting
Forging ‫الحدادة‬ ‫سباكة االسطمبات‬
‫لحام القوس الكهربي‬ Drilling ‫الثقب‬
SMAW, GTAW, SAW Die Casting
Extrusion ‫البثق‬
‫لحام القوس المعدني‬ ‫الشمع المفقود‬
Milling ‫التفريز‬
GMAW ‫المغطى بالغاز‬ Bending ‫الثني‬ Investment Casting

‫لحام المقاومة الكهربية‬ Drawing ‫السحب‬ ‫الصب المستمر‬

Planing ‫الكشط‬
Resistance Welding Continuous Casting

‫لحام االحتكاك‬ Grinding ‫التجليخ‬ ‫السحب العميق‬

Friction Welding Deep Drawing

Manufacturing Processes - ME 205 Forming - 2

 Overview of Metal Forming Processes
Plastic deformation:
 Operations that induce permanent shape changes on the
work piece by application of external forces with the aid of
tools and dies.

Bulk Deformation
 Plastic deformation processes that involve large amount
of 3D or volumetric deformation. Carried out at hot, warm
or cold working conditions.

Sheet forming processes

 Plastic deformation processes performed on thin sheets
(less than 6 mm), strips or coils of metals. They are almost
performed as cold working operations.
Manufacturing Processes - ME 205 Forming - 3
 Cold and Hot Working of Metals
Most metal working (Forming) processes can be Hot, Warm or
Cold working processes.

 Hot working processes:

 Above 50% of melting point
 No work hardening
 No fear of component failure
 Hot working causes slag, porosity and inclusions
 Poor surface finish and inaccurate dimensions
Manufacturing Processes - ME 205 Forming - 4
 Cold and Hot Working of Metals
 Cold working processes:
 Below 30% of melting point
 Significant work hardening takes place
 Residual stresses are usually introduced
 Repeatable accurate components
 Good surface finish
 Cold working forces are very much higher than forces
during hot forming

Manufacturing Processes - ME 205 Forming - 5

 ‫عمليات الدرفلة‬
Rolling Processes

Manufacturing Processes - ME 205 Forming - 6

 1. Rolling Process
The cast metal usually requires
reshaping by Rolling
Rolling is the process of changing
the cross sectional shape and
dimensions through passing the
metal section between two flat or
shaped rolls.
Almost all metals and their alloys
begin life by casting.

The gap between the rotating rolls is less than the thickness of the
entering bar h0 therefore a friction force is necessary in order to bite
the bar and to pull it through the rolls

Manufacturing Processes - ME 205 Forming - 7

 Flat and Shape Rolling Operations
 The majority of steel
products are being
converted from the ingot
form by the process of
rolling.

 The basic operation is flat

rolling, or simply rolling,
where the rolled products
are flat plates and sheets. Source:
Kalpakjian
Manufacturing Processes - ME 205 Forming - 8
 Examples of Shape Rolling

Stages of Round Bar Rolling

Examples of Rolled Section at Different Stages

Stages of Rolling T-Sections

Manufacturing Processes - ME 205 Forming - 9
 Rolling Operation

Manufacturing Processes - ME 205 Forming - 10

 Rolling Mills

Manufacturing Processes - ME 205 Forming - 11

 Elementary Mechanics of Rolling
 Absolute Reduction: the difference
between the initial and final
thickness :
∆H= H1 - H2

 Relative Reduction: the ratio of the

absolute reduction to the initial
thickness:
H1  H 2 H
R 
H1 H1
 Percentage Reduction
H1  H 2 H
%R   100
H1 H1
Manufacturing Processes - ME 205 Forming - 12
 Elementary Mechanics of Rolling
 Due to the assumption of volume constancy

B1.L1.H1 = B2.L2.H2

 Since the amount of breadth change is relatively

neglected (i.e. B1≈B2),

H 1 L1
H2 
L2

Manufacturing Processes - ME 205 Forming - 13

Manufacturing Processes - ME 205 Forming - 14
 Condition of Rolling Bite
 Both rolls act with normal force N over
the contact arc α, which results in a
tangential friction force F

 The central angle α can be calculated

based on the absolute reduction and
roll diameter as follows:
H
Cos  1 
Droll

 Hence the absolute reduction can be

calculated as:
∆H = Droll( 1 – cosα )

Manufacturing Processes - ME 205 Forming - 15

 Condition of Rolling Bite
 As shown in figure, the components of
the normal and friction forces N , F are:
 S components: squeezing the metal
 Q components: forward rolling action
 P components: resistance to rolling
S = N cos α + F sin α
Q = F cos α
P = N sin α
 In order to succeed in rolling action: Q >P
F cos α > N sin α (1)
hence,
F = µN (2)
Resulting in the condition of rolling bite:
µ > tan α
Manufacturing Processes - ME 205 Forming - 16
 Rolling Stand Arrangements

Manufacturing Processes - ME 205 Forming - 17

 Types of Rolling Stands (cont.)
Four-High Rolling Mill
 It is essentially a two-high rolling
mill, but with small sized rolls.
Practically, it consists of four
horizontal rolls, the two middle
rolls are smaller in size than the
top and bottom rolls.
 The smaller size rolls are known
as working rolls which
concentrate the total rolling
pressure over the workpiece.

Manufacturing Processes - ME 205 Forming - 18

 Types of Rolling Stands (cont.)
Cluster Mill
 It is a special type of four-high rolling mill in which each of
the two smaller working rolls are backed up by two or more
of the larger back-up rolls as shown.
 This type of mill is generally used for cold rolling of hard
thin materials, where the needed forces are extremely
high.

Manufacturing Processes - ME 205 Forming - 19

 Rolling Defects
 Waviness: Improper or not constant roller speeds
 Zipper cracks: too high rolling forces in center
 Edge cracks: too much rolling on outside
 Alligatoring: too much induced tensile residual stresses in
the outer layers of the part

Manufacturing Processes - ME 205 Forming - 20

 ‫عمليات الحدادة‬
Forging Processes

Manufacturing Processes - ME 205 Forming - 21

 Forging Process
 Forging produces products as near to
the final shape as possible by applying
compressive forces.
 Forging can be used to manufacture
Cross Section in a Forging parts from a wide range of metals,
especially steels and aluminum alloys.
 A most important feature of forging is
that the produced components have
improved strength and toughness .
 Forging is used for the production of
highly stressed components such as
crankshafts and connecting rods for car
Example of Die Forging engines.
Manufacturing Processes - ME 205 Forming - 22
 Examples of Forgings

Pedal Force

Schulte-Ufer

Sparco

Phi-Tool

Mahle Presswerk Krefeld

Manufacturing Processes - ME 205 Forming - 23

 Open Die Forging
 The work piece is usually heated above its recrystallization
temperature.
 The workpiece is squeezed into the required shape with a
hammer (manual or power hammer).

 Friction is an important
factor that influences the
forging forces, the die
filling and the accuracy of
the product.
Manufacturing Processes - ME 205 Forming - 24
 Open-Die Forging Operations
Advantages
 Simplest type of forging.
 Dies are inexpensive.
 Wide range of part sizes,
ranging from 15-500 kg.
 Generally good for small quantities.
Limitations
 Simple shapes only.
 Difficult to hold close tolerances.
 Machining necessary.
 Low production rate.
 Poor utilization of material.
 High skill required.
Manufacturing Processes - ME 205 Forming - 25
 Free Open Die Forging

Manufacturing Processes - ME 205 Forming - 26

 Closed Die Forging with Flash
(Impression or Drop Forging)
 If a large number of identical components are
required, closed-die drop forging may be used.

Manufacturing Processes - ME 205 Forming - 27

 Examples of Multistages Forging Dies

Manufacturing Processes - ME 205 Forming - 28

 Impression-Die Forging
Advantages
 High production rates.
 Good dimensional accuracy.
 Good reproducibility.
 Relatively, good utilization of material.
 Dies can be made of several pieces and inserts to create more
advanced parts.
 Better properties than open-die forging.
 Presses can go up to 50,000 ton capacities.
Disadvantages
 High die cost.
 Machining is often necessary after forging.
 Only economical for large quantities.
Manufacturing Processes - ME 205 Forming - 29
 Precision Forging
 The process involves applying lengthwise impact
pressure to one end of the blank, and forging it into
the final required shape.
 This process is particularly useful for large-quantity
production of bolts.

Manufacturing Processes - ME 205 Forming - 30