Chapter 3:

METAL FORMING PROCESSES

THROUGH PLASTIC DEFORMATION

Group 9:
- Trần Vũ Hảo - 2052978
- Nguyễn Lê Nhật Khang - 2053100
- Nguyễn Võ Trung Tài - 2053414
- Lê Thái Bảo - 2052873
3.1/ROLLING.
3.3.1. Rolling Principle Rolling is a metal forming process in which the thickness of the
workpiece is reduced by compressive forces acting on it through two rolls. There are
two common types of rolling processes: flat rolling and shape rolling.
•Flat rolling is used to reduce the thickness of components with rectangular cross-
sections. It transforms sections into shapes like I-beams, L-shapes, U-shapes, as well as
square, round, or rail steel.
•Rolling is carried out at high temperatures, known as hot rolling, and is predominantly
used in heavy industries. This method aims to reduce the rolling force, eliminating
residual stress.
•Rolling at normal temperatures is referred to as cold rolling. After hot rolling, products
undergo cold rolling to reduce length, enhance dimensional accuracy, decrease surface
roughness, and increase hardness.
• In addition to shaping, cold rolling imparts improved mechanical properties to the
products.
3.1/ROLLING.
3.1.2 Rolling Mills
•There are various types of rolling mills depending on the requirements of the product.
The most basic rolling mill consists of two rolls with diameters ranging from 0.6 to 1.4
meters. These rolls can rotate in either the same direction or in opposite directions.
3.1/ROLLING.
3.3.3. Other Rolling Processes.
•Thread Rolling The thread rolling method is employed for producing components with
external threads, especially those that do not require high precision. The thread rolling
process is carried out at low temperatures.
•https://www.youtube.com/watch?v=yLBWP2gx-U0&ab_channel=PACVietnamTechno
logy
3.2/FORGING.
•Forging is a fundamental bulk deformation metal processing method where the
workpiece is shaped through plastic deformation within a mold, exerted by the
compressive force of the mold or similar tools. There are three basic forging methods:
open-die forging, closed-die forging, and flashless forging.
•Forging is one of the oldest and most significant metal processing methods in human
history. Initially used for crafting jewelry, coins, and metal tools with stone-made
forging tools, it has evolved into a crucial manufacturing process.
•Even today, various components are manufactured through forging methods, including
large fan blades for turbines, gears, bolts and rivets, shears, hand tools, structural
components for railway tracks, and other high-strength mechanical parts used in
automobiles.
3.2/FORGING.
•Most forging processes are conducted at high temperatures, known as hot forging.
However, it can also be done at normal temperatures, known as cold forging. Hot
forging requires lower force but results in lower precision and surface roughness
compared to cold forging. Typically, forged products often undergo additional
machining processes to enhance precision and reduce surface roughness.
•Key equipment used in forging processes includes forging machines, molds, and
auxiliary tools such as heating furnaces, devices for supplying and removing
workpieces, and flash-cutting equipment if needed.
• Forging machines can be either hammers or presses. Hammers generate impact forces
with a cyclic pattern, while presses apply steady forces at slower speeds. Presses can
be driven by mechanical or hydraulic systems. Mechanical presses often generate
very high forces, reaching several thousand tons.
3.2/FORGING.
3.2.1 Open-Die Forging
• Open-die forging is the simplest forging method. The products of open-die forging
can range in size from very small to very large, and while they can be diverse, they
generally have simple shapes.
•the part. This method is used to process gear blanks
•that require high mechanical properties
•width and length As the part rotates, the pressure on the upper and lower molds
reduces the diameter Some common applications of open die forging method in industry
•In which, picture a: reduces the size of the detail according to height and increases the
size according to the detail down. Figure c: ring machining using open die forging
method. By increasing the pressure of the upper die when turning the part all the way
around, we can increase the diameter and reduce the thickness of
3.2/FORGING.
3.2.1. Open-Die Forging
• Open-die forging is the simplest forging method. The products of open-die forging
can range in size from very small to very large, and while they can be diverse, they
generally have simple shapes.
•The part. This method is used to process gear blanks
•That require high mechanical properties
•Width and length As the part rotates, the pressure on the upper and lower molds
reduces the diameter Some common applications of open die forging method in industry
•In which, picture a: reduces the size of the detail according to height and increases the
size according to the detail down. Figure c: ring machining using open die forging
method. By increasing the pressure of the upper die when turning the part all the way
around, we can increase the diameter and reduce the thickness of
3.2/FORGING.
3.2.1 Open-Die Forging
https://youtube.com/shorts/UtL70Gze27A?si=IV0q79ypfuUfXXDT
3.2/FORGING.
3.2.2. Forging closed mold
• In the closed die forging method, the product has the shape of the die cavity, this
shape is obtained when the die is pressed and deformed plastically in the die cavity.
This process is often performed at high temperatures to reduce pressing forces and
achieve the requirement of increasing the ductility of the workpiece

•Normally, the billet entering the closed die forging process must go through many
preliminary forging steps to get a shape similar to the product to reduce pressure as well
as the ability to fill the mold cavity.
3.2/FORGING.
3.2.2. Forging closed mold
•1: Forging mold
•2: groove containing burrs
•3: Lower mold
•4; Swallow tail hilt
•5: Mold cavity
•6: Door bur
3.2/FORGING.
Advantage:
•High precision gloss.
•Mechanical properties of forged objects are uniform.
•The detailed shape is more complex than open forging.
•Save materials.
•Simple operation, worker level does not need to be high.
• High productivity.
3.2/FORGING.
Defect:
•High mold cost
•Molds often wear out
•The volume of forging is smaller than free forging
•https://www.youtube.com/watch?v=_CHxLAbCjJw&ab_channel=%E3%83%97%E3%83%AD%E3%8
2%BB%E3%82%B9X
3.2/FORGING.
3.2.3 Forging without burrs
•In principle, burrless forging is the same as closed die forging. However, it requires
accurate calculation of the product volume to create accurate blanks, the tolerance range
is very small, the product does not need to be deburred.
Advantage:
•Less metal consumption
•Good permeability.
3.2/FORGING.
Defect:
•Must calculate the entire embryo accurately
•Principle of burr-free method:
3.2/FORGING.
A variation of this method is the process of increasing the diameter and reducing the
length of one part, while leaving the other parts unchanged.
•Steps of rivet machining process:
•(1) The workpiece is cut accurately
•(2) The part that does not change size is clamped tightly
•(3) The mold is pressed to form the rivet head
•(4) The rivet head is completed
3.2/FORGING.

•https://youtube.com/shorts/I8vdrdmO7m0?si=4QASDb3HbxlWW9Xb
•THIS IS A MANUFACTURING PROCESS.
3.3/EXTRUSION.
Extrusion is a compression process in which a metal billet is forced to flow through an
open die to create the desired cross-section. Some advantages of the extrusion method:
Creates details with diverse cross-sections, especially hot extrusion; Improved grain
structure, increasing mechanical properties of the product, especially when cold
extruded;
•Dimensional accuracy is quite high
•High level of material usage
The biggest limitation of this method is that the products have a constant longitudinal
cross-section of the product.
3.3/EXTRUSION.

3.3.1 Classification of using methods

Direct extrusion and indirect extrusion.
Characteristic
•In direct extrusion process extruded metal flows in direction of ram motion
•Force required to release billet out of extruder is more
•Direct extrusion process is also known as forward extrusion
•Material waste is more
•Frictional force is high
3.3/EXTRUSION.

3.3.1 Classification of using methods

Direct extrusion and indirect extrusion.
3.3/EXTRUSION.

3.3.1 Classification of using methods

Direct extrusion and indirect extrusion.
Characteristic.
•In direct extrusion process metal flows in opposite direction to ram motion
• In direct extrusion process requires lower force than direct extrusion
process as there is no friction between billet and inside walls of container.
Extrusion at high temperature and low temperature
•Most metals such as aluminum, magnesium, copper and aluminum and
magnesium alloys are extruded at high temperatures, however some metals
such as aluminum can be extruded at low temperatures. Often individual
3.3/EXTRUSION.
3.3.2 Some other extrusion methods
Extrusion on a press
• This method is often performed on a press instead of an extruder like the above
methods. Figure 3.15 illustrates the principle that individual pellets are made first,
then the extrusion process is carried out through fire and mortar on a press with 5
high speeds to obtain the product of this method, in the figure, the following figures:
desired shape and size.
3.3/EXTRUSION.
3.3.2 Some other extrusion methods
Hydrostatic extrusion
Figure 3.16 describes the principle of hydrostatic extrusion, the extrusion force is
created by a high pressure hydraulic system. This method creates even pressure and
reduces pressure, resulting in a compact machine structure.
3.4/SHEET METAL FORMING.
I. Introduction.
•Sheet metal forming is the process of turning a flat sheet of steel (or other material, such
as aluminum or copper or titanium) into a complex 3D shape, such as those seen in
vehicles or aircraft.
•Sheet metal forming is nearly always done with hard “tooling”, which can be placed in a
high-speed production press, and stamp parts out very efficiently, usually at rates such as
30 parts per minute or higher.
•Because of the very high efficiency of sheet metal forming for large volumes of parts, no
other process has ever come close to replacing sheet metal forming.
3.4/SHEET METAL FORMING.
II. Shearing operation.
•Shearing is the mechanical cutting of materials without the formation of chips or the use
of burning or melting
•Shearing operation: blanking, fine blanking, perforating, notching, lancing, slitting…
•The most common shearing operations are punching or blanking.
3.4/SHEET METAL FORMING.
II. Shearing operation.
1. BLANKING
3.4/SHEET METAL FORMING.
II. Shearing operation.
1. BLANKING
•The major processing parameter in shearing are:
•The shape of punch and hole.
•The clerance, c, between the punch and die.
•The speed of punching
•Lubrication
•The clearance is a major factor in determining the shape and the quality of the sheared
edge. As clearance increases, the deformation zone becomes larger and the sheared-edge
surface becomes rougher.