FORMING PROCESSES

➢ Forming is a deformation based approach used to give the

desired size and shape.
➢ Therefore, all factors affecting the deformation tendency
(ductility, yield strength, strain hardening) will eventually affect
the performance of the forming processes.
➢ In General an increase in the Temperature results in
❖ Decrease in Strength
❖ Increase in Ductility
❖ Decrease in the Rate of Strain Hardening
➢ All these effects ease of deformation required for forming
➢ On the basis of forming Temperature forming processes
can classified as
❖ COLD Forming
❖ WARM Forming
❖ HOT Forming

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 COLD FORMING HOT FORMING
Below their Recrystallization Above their Recrystallization
Temperature Temperature

Temperature of Deformation < Temperature of Deformation

0. 3 Melting Temperature on > 0.6 Melting Temperature on
the Absolute Scale the Absolute Scale
Recrystallization Temperature
Varies Greatly with the
Material
→ Tin is Near Hot-Working at
Room Temperature while Steel
Require Temp. near 2000oF

WARM FORMING: Deformation Between 0.3 to 0.6 Times the

Melting Point on the Absolute Scale

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 Hot Working Cold Working
Processes
→Forging Squeezing: Cold Rolling, Cold
→Rolling Forging , Cold Extrusion,
→ Extrusion Coining, Peening, Burnishing,
→ Hot Drawing and Thread Rolling.
→ Piercing Bending: Angle Bending, Roll
Bending, Roll-forming, and
Straightening.
Shearing: Slitting, Blanking,
Piercing, Notching, Nibbling,
Drawing: Spinning, Embossing,
Stretch Forming, and Ironing
Sheet-metal Forming
Operations

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 FORGING Drawing Out
➢ Involves application of force on metal to
cause plastic deformation so as to get the
required final shape.

➢ Forging is Generally a Hot Working but also

be Cold Forging.

➢ Forging can be done in two ways

❖ Drawing Out: Elongates the object with

a Reduction in the Cross-Sectional Upsetting
Area using Force Applied in a Direction
Perpendicular to the longitudinal Axis.

❖ Upsetting: increases the Cross-

Sectional Area of the Stock at the
Expense of its Length using Force
Applied in a Direction Parallel to the
Length Axis.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 FORGING TYPES
Smith Forging: Traditional Forging
performed using Open Dies with help of
Manual or Powered Hammers.
➢ Drop Forging: uses Closed Impression
Dies by Means of Drop Hammers in a
Series of Blows.
➢ Press Forging: is Similar to Drop Forging
with the Difference that the Force is a
Continuous Squeezing Type.
➢ Machine Forging: the Material is only
Upset to Get the Desired Shape using a set
of dies.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE
SMITH FORGING

➢ Involves Heating the Stock in the Blacksmith's Hearth and

then Beating it Over the Anvil.
➢ The stock is Manipulated in Between the Blows.
➢ Used for low volume production of variety of designs.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

➢ The Drop Forging Die Consists of Two Halves.
❖ The Lower Half is Fixed to the Anvil of the
Machine,
❖ While the Upper Half of the Die is Fixed to
the Ram.
❖ The Heated Material Stock is Kept in the
Lower Die while the Ram Delivers Four to
Five Blows on the Material, in Quick
Succession so that the Material Spreads and
Completely Fills the Die Cavity.
❖ When the Two Die Halves Close, the
Complete Cavity is Formed.
➢ Since the Machined impressions in the Die
Cavity help to get more Complex Shapes in
Drop Forging as Compared to Smith Forging

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 Drop forging

MI-102: Manufacturing Techniques I. I. T. ROORKEE

➢ Typical Products Produced by Drop Forging are Crank, Crank
Shaft, Connecting Rod, Wrench, Crane Hook, etc.

➢ Final Shape Desired in Drop Forging Cannot be Obtained

Directly from the Stock in a Single Pass.
➢ Depending on the Shape of the Component, and the Desired
Grain Flow Direction, the Material should be Manipulated
in a Number of Passes.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

FULLERING IMPRESSION: Reducing Stock to the
Desired Size.

EDGING IMPRESSION (Preforming): Ensures

Defect-Free Flow of Material, Complete Die Fill and
Minimum Flash Loss.
BENDING IMPRESSION: for the Parts having a
Bent Shape.
BLOCKING is a Step before Finishing. The Material
Flows to Deep Pockets, Sharp Corners, etc.
before the Finishing Impression without Flash.
FINISHING: is the Final Impression for Actual
Shape .at this stage a Little Extra Material is
Added to the Stock Forms the Flash and
Surrounds the Forging in the Parting Plane.
TRIMMING is removal of the Extra Flash Present
Around the Forging to make the Forging in Usable
.
MI-102: Manufacturing Techniques I. I. T. ROORKEE
PRESS FORGING

➢ In Press Forging, involves Single Continuous Squeezing

Action results in Uniform Deformation Throughout the
Depth.

➢ The Impressions Produced in the Press Forging are

Cleaner as Compared to the Jarred Impressions Produced
in the Drop Forged Components.

➢ Press forging suits for smaller size components than drop

forging as former needs higher Press Capacity for Deforming
in Closed Impression Dies. No such Limitation for Press
Forging in Open Dies.

➢ Presses Capacities May Range from 5 MN to 50 MN for

Normal Applications and as High as 600 MN for Special
Heavy Duty Applications.
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 MACHINE FORGING
➢ Initially Developed for Making the Bolt Heads in a
Continuous Fashion.
➢ Due to Beneficial Grain Flow Obtained in Upsetting, it is Used
for Making Gear Blanks, Shafts, Axles and Similar Parts.
Some Typical Parts Produced by Upset Forgings are Shown in
the Figure.
➢ The Die Set Consists of a Die and a Corresponding Punch or a
Heading Tool.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MACHINE FORGING
➢ The Upset Forging Cycle
❖ Movable Die comes closer to Stationary Die to Grip
the Stock.
❖ The Two Dies in Closed Position Form the
Necessary Die Cavity.
❖ The Punch Upsets stock to Fill the Die Cavity.
❖ After Upsetting, Punch Moves Back to its Position.
❖ Movable Grippes Release the Stock.
➢ Similar to Drop Forging, the Upsetting Operation is
Carried Out in a Number of Stages or Passes.
➢ The Material Stock is Moved from One Stage to the
Other in a Proper Sequence Till the Final Forging is
Ready.
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 Some Typical Upset or Machine Forged Components
MI-102: Manufacturing Techniques I. I. T. ROORKEE
FORGING DEFECTS
➢ Unfilled Sections: of Die Cavity by the Flowing Material due to:
❖ Improper Design of Forging Die or
❖ Faulty Forging Techniques.

➢ Cold Shut: A Small Crack at the Corners of the Forging due to

Improper Design of the Die e.g. Corner and Fillet Radii are
Small which in turn results in small cracks due to poor flow of
materials at the Corner.

➢ Scale Pits: Irregular Depressions on the Surface of the Forging

primarily due to improper Cleaning of the Stock Used for Forging.

➢ The Oxide and Scale Present on the Stock Surface Gets

Embedded into the Finished Forging Surface. When the Forging
is Cleaned by Pickling, these are Seen as Depressions on the
Forging Surface.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

➢ Die Shift:
CAUSES: Die Shift is Caused by the
❖ Misalignment of the Two Die Halves
Making the Two Halves of the Forging to
be of Improper Shape.

➢ Flakes: These are Basically Internal

Ruptures due to poor ductility of surface
layer during deformation caused by Rapid
Cooling

MI-102: Manufacturing Techniques I. I. T. ROORKEE

ROLLING
➢ Rolling is a Process where the Material is Compressed
Between Two Rotating Rolls for Reducing its Cross-
Sectional Area.
➢ Rolling is Normally a Hot Working Process unless specified
as Cold Rolling.
➢ At Entry, the Surface Speed of Rolls is Higher than that of
the Incoming Material, whereas the Material Velocity at the
Exit is Higher than that of the Surface Speed of the Rolls
due to difference cross sectional area.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 Scheme of Rolling Process
MI-102: Manufacturing Techniques I. I. T. ROORKEE
Animation

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 ❖ Rougher Rolls Give Achieve Greater Reduction than
Smoother Rolls.
❖ But, the Rough Roll Surface may Get Embedded into the
Rolled Metal thus Producing Rough Surface.
➢ The Reduction that could be Achieved with a Given Set of Rolls
is Designated as the Angle of Bite. This Depends on the Type of
Rolling and the Conditions of the Rolls as shown in Table.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

Typical Rolled Shapes
MI-102: Manufacturing Techniques I. I. T. ROORKEE
ROLLING STAND

2-High Rolling Stand:

➢ Direction of Roll Rotation
can be Reversed which
reduces Handling of the
Hot Material in Between
the Rolling Passes.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

3-High Rolling Stand:

➢ Arrangement is Used for Rolling of Two

Continuous Passes in a Rolling Sequence
without Reversing the Drives.

➢ A Table-Tilting Arrangement is Required to

Bring the Material to the Level with the Rolls.
MI-102: Manufacturing Techniques I. I. T. ROORKEE
4-High Rolling Stand:
➢ Backup Rolls for Providing the Necessary Rigidity to the
Small Rolls and offers advantage of high reduction.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

➢ Since Required Final Shape Cannot be Obtained in
a Single Pass
❖ The Rolling Mills are Generally need More
than One Pass to other stands or by Reversing
the Roll Direction or

➢ The Steel Ingot: 600 x 600 mm. These Ingots are

Further Processed in Rolling Mills to Produce the
Intermediate Shapes such as Blooms, Slabs and
Billets.

❖ Blooms: 150 x 150 mm to 400 x 400 mm

(square).
❖ Slabs: 500 to 1800 mm and Thickness from
50 to 300 mm (rectangle).
❖ Billets: from 40 x 40 mm to 150 x 150 mm
(rectangle).
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 ROLL PASSES

Roll Pass Sequence can be Broadly Categorized into

THREE Types:

1. Break Down Pass:

➢ Used for Reducing the Cross-Sectional Area
Nearer to what is Desired.
2. Roughing Pass:
➢ The Cross-Section Gets Reduced, but Shape of
the Rolled Material also Comes Nearer to the
Final Shape.

3. Finishing Pass:
➢ Gives the Required Shape of the Rolled
Section.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 DRAUGHT
➢ If the Cross Section of the Product Before and
After Rolling Process is A x B and a x b Respectively,
DRAFT is Defined as (A + B)- (a + b)
➢ Roll Pass Schedule can be obtained from
Draught.
➢ If Mean Draught for Each Pass is Known, then
Number of Passes can be Estimated.
➢ Draught Provided in Each Pass
also Depends on the
❖ Work Material,
❖ Angle of Bite,
❖ Roll Strength,
❖ Power of the Rolling Mill
❖ Surface Condition of Rolls.
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 Selection of draught
➢ Draughts of All the Passes in the Rolling
Sequence are NOT the Same.
❖ The Main Criteria for Choosing the Draught is
the Angle of Bite.
➢ LOWER DRAUGHT IS USED IN SUBSEQUENT
PASSES.
➢ Reason for Reducing Draught in the Later
Passes:
➢ in Hot Rolling is the Reduction in Stock
Thickness which Causes it to Lose Heat
Quickly and thus Increases the Rolling Load.
➢ in Cold Rolling, the Strain Hardening of the
Stock Material Necessitates a Reduction in
Draught in the Succeeding Passes.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

EXTRUSION
➢ Like plastic extrusion, the Material is Confined in a
Closed Cavity and then Forced to Flow From Only One
Opening so that the Material Takes the Shape of the
Opening.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 ➢ Used to Make Components having a Constant Cross-Section
over any Length.
❖ More Complex Parts can be Obtained by Extrusion than
that of Rolling, as Die become Simple and Easier to
Make.
➢ Extrusion is a Single Pass Process.
➢ The Amount of Reduction Possible in Extrusion is Large.
➢ Generally Brittle Materials can Also be Very Easily Extruded.

Typical
Extrusion
Shapes

MI-102: Manufacturing Techniques I. I. T. ROORKEE

➢ Extrusion Ratio is Defined as the Ratio of
Cross-Sectional Area of the Billet to that of
the Extruded Section.
❖ Typical Values of the Extrusion Ratio are 20
to 50.
➢ The Extrusion Pressure for a Given Material
Depends on the
❖ Extrusion Temperature,
❖ Reduction in Area, and
❖ Extrusion Speed

MI-102: Manufacturing Techniques I. I. T. ROORKEE

CLASSIFICATION OF EXTRUSION PROCESS

MI-102: Manufacturing Techniques I. I. T. ROORKEE

FORWARD HOT EXTRUSION
➢ The Direction of Flow of Material is the Same as that of the
Ram.
➢ Friction is Important Because of the Relative Motion
Between the Heated Material Billet and the Cylinder Walls.
❖ Lubricants are to be used To Reduce this Friction.

❖ For Low
Temperatures:,
Oil Mixture and
Graphite
❖ For High
Temperature,
Molten Glass
for Extruding
Steels.

Forward Extrusion
MI-102: Manufacturing Techniques I. I. T. ROORKEE
BACKWARD or INDIRECT HOT EXTRUSION

➢ The Ram Compresses the Material Against the Container,

Forcing the Material to Flow Backwards through the Die
in the Hollow Plunger or Ram.

➢ Since Billet in the Container Remains Stationary → No

Friction.
➢ Extrusion Pressure
is Not Affected by
the Length of the
Billet as friction is
absent
➢ Problem is
imposed by
Handling of
Extruded Material
Coming Out
through the Backward Extrusion
Moving Ram.
MI-102: Manufacturing Techniques I. I. T. ROORKEE
FORWARD COLD EXTRUSION
➢ Forward Cold Extrusion is Similar to the Forward Hot
Extrusion Process Except with low Extrusion Ratios and high
Extrusion Pressures.
➢ Used for Simple Shapes with Better Surface Finish and
Mechanical Properties.

IMPACT EXTRUSION

It is modification of Backward Cold Extrusion Carried Out by

the Impact Force of the Punch.
➢ Material is Extruded through the Gap Between the Punch
and Die Opposite to the Punch Movement.
➢ Suitable for Softer Materials such as Aluminum and its
Alloys.
➢ Used for Making the Collapsible Tubes for Housing Pastes,
Liquids and similar Articles.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 Impact Extrusion

MI-102: Manufacturing Techniques I. I. T. ROORKEE

COLD EXTRUSION FORGING:
➢ The Cold Extrusion Forging is Similar to Impact
Extrusion, the
❖ Main Difference being the Side Walls much Thicker
and with More Height.
➢ The Component is Ejected by Means of the Ejector Pin
Provided in the Die

MI-102: Manufacturing Techniques I. I. T. ROORKEE

HYDROSTATIC EXTRUSION:

➢ The Material Billet is Compressed from all Sides by

a Liquid Rather than the Ram.
➢ No Lubricant and Material is Uniformly
Compressed from All Sides throughout the
Deformation Zone.
❖ Consequently Highly Brittle Materials such as
Grey Cast Iron can also be Extruded.
➢ Commercial Applications of the Hydrostatic
Extrusion are Limited to
❖ Extrusion of Reactor Fuel Rods,
❖ Cladding of Metals, and
❖ Making Wires of Less Ductile Materials.
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 Hydrostatic Extrusion

MI-102: Manufacturing Techniques I. I. T. ROORKEE

DRAWING
WIRE DRAWING
➢ Wire Drawing is a cold working process to Obtain Wires
from Rods of Bigger Diameter through a Die.
❖ The End of the Rod is Made into a Point Shape and
Inserted through the Die Opening then Pull the Wire
through the Die with held of griper
➢ Material to be Wire Drawn should be Sufficiently Ductile.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

Various Die Materials Used are Chilled Cast Iron,
Tool Steels, Alloy Steels, Tungsten Carbide and Diamond.

Wire Drawing Set Up

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 TUBE DRAWING

➢ In Tube Drawing, a Mandrel of the Requisite Diameter is

Used to Form the Internal Hole.
➢ The Tubes are also First Pointed and then Entered through
the Die where the Point rod is Gripped in Similar way as
the Wire Drawing and Pulled Through.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

SHEET METAL OPERATIONS
➢ Metal Sheet: Plates of thickness < 5 mm
➢ Sheet metal operations use different types
of stresses for processing
➢ Shear stress is primarily used in sheet
metal processing
Stress Induced Operations
Shearing Shearing, Blanking, Piercing,
Trimming, Shaving, Notching,
Nibbling
Tension Stretch-Forming
Compression Ironing, Coining, Sizing, Hobbing
Tension and Drawing, Spinning, Bending,
Compression Embossing, Forming
MI-102: Manufacturing Techniques I. I. T. ROORKEE
SHEARING
➢ The Sheet IS deformed between two shearing
Blades (developing tensile and compressive stress).
➢ Then cracks nucleate and grow when material near
cutting edges is elongated beyond fracture limit which
later join for separation.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

BLANKING:
➢ Process of obtaining a small piece of strip by cutting
(shearing from the Stock with help of a Punch.
➢ The removed strip is Called Blank used for further
processing to get useable product.

PUNCHING:
Similar to blanking
except
that objective is to
make Holes in
Sheet
and removed strip is
considered as scrap

Blanking/Punching Die
MI-102: Manufacturing Techniques I. I. T. ROORKEE
WITHOUT
PROPER
GRIPPING
OF SHEET

ROUGH
EDGE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

WITH
PROPER
GRIPPING
OF SHEET

MI-102: Manufacturing Techniques I. I. T. ROORKEE

TRIMMING:

➢ Removing Small Amount of Extra Material Spread Out Near

the Parting Plane such as Drop Forging and Die Casting.

SHAVING
➢ Removal of the Burrs Generated during the Shearing Process
in the Blanking or Punching Operation so as to achieve the
Close Tolerance Work.
NIBBLING:
➢ Removing the Material in Small Increments to Cut a Specific
Contour on a Sheet using repeating Punching.

➢ Nibbling is Used When the Contour is Long and a Separate

Punch is Impractical and Uneconomical.

NOTCHING: Cutting a Specified Small Portion of Material

Towards the Edge of the Material Stock.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE
 SHEET METAL OPERATIONS INVOLVING
TENSION
STRETCH-FORMING
➢ The Sheet is Clamped at ends and Stretched over the
Die so as to achieve plastic State and permanent
deformation.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 Stretch forming

MI-102: Manufacturing Techniques I. I. T. ROORKEE

SHEET METAL OPERATIONS INVOLVING COMPRESSION
IRONING

It involves thinning and lengthening of the wall

of material by generating compressive stress
between the Die and Punch having using the
Clearance (spacing) finer than the Drawing
Operation.

➢ Up to 50%
thinning can
be obtained in
a Single
Ironing
Operation

Ironing Operation
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 COINING
➢ It is just like a Cold Forging Operation except that the
Flow of the Material Occurs Only at the Top Layers
and NOT in the Entire Volume.
➢ The Punch and Die have Engraved Details Required on
Both Sides of the Final Object and uses high pressure
(1600 MPa) to get Fine Details on the Surface.

❖ For Making
Coins, Medals
& Impressions
on Decorative
Items

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 SHEET METAL OPERATIONS INVOLVING
TENSION and COMPRESSION
DRAWING/DEEP DRAWING
➢ Drawing is the Process of Making Cups (high < half
diameter), and similar product, from Metal Blanks.
➢ When the Cup Height is More than Half the Diameter, the
Drawing Process is known as Deep Drawing.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 Blank Holding in
Deep Drawing

MI-102: Manufacturing Techniques I. I. T. ROORKEE

SPINNING
➢ Used for Making Axi-Symmetrical Cup Shaped Articles.
➢ Force (moving) is Applied on the Rotating Blank is Held
Against the Form Block so as get Shape of the Form Block
(of wood).

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 BENDING
➢ Operation of Deforming a Flat Sheet Around a Straight
Axis at the Neutral Plane.
➢ When material is subjected to plastic deformation, the
Neutral Axis Moves Downward due to differential strain
on both sides of neutral axis as the Materials Oppose
Compression in much Better way than Tension.
➢ Nomenclature of Bending and Type of Bending Methods
are Shown in Following Figures.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 Nomenclature of Bending
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 Type of Bending Methods
MI-102: Manufacturing Techniques I. I. T. ROORKEE
EMBOSSING

➢ An Operation for Making Raised Figures/letter on

Sheets with its Corresponding Relief on the Other Side.
➢ The Process Involves Drawing and Bending of the
Material.
➢ Generally Used for increasing the Rigidity by localized
deformation and for Decorative Sheet Work.

MI-102: Manufacturing Techniques I. I. T. ROORKEE