)

(

.

Metals are solid materials at room temperature ( except

mercury which is liquid), have relatively high melting point,
good conductors of heat and electricity, and usually strong &
malleable so they can be hammered into shape.

Metal Forming Advantages:

Good surface finishing and dimensions accuracy

Wide variety and complicity of profiles
Improving the mechanical properties of the product
High productivity without affecting the quality

:

:

. ( )

0.75 0.3
)
. (

Metal forming according to the forming temperature:

Cold forming - Hot forming ;
It is cold forming when the forming process takes
place at the room temperature;
It is hot forming when the forming temperature is
between 0.3 0.75 of the metal melting point (Tm) ,
i.e. above the Recrystallization point.

Cold Formation

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AIU Faculty of Fine Arts Workshop 3

Advantages

disadvantages

(annealing)

Higher forces and power

Better accuracy, and less
are required
tolerances
The surface should be
Better surface finishing
cleaned
The strain-hardening
ductility and strainincreases the strength and
hardening limits the extent
the hardness of the product
of forming
No heating is needed
requires ductile metals

Hot Formation
Advantages
Less forces and power are
required
No strain-hardening
More complicated and
detailed products are
applicable
No need for annealing
Larger deformation

disadvantages

Less dimensions accuracy
Require more power for

the heating process

Oxidization and scaling

give poor surface finishing

The heating strains might

shorten the products

working life

(annealing)

Bulk formation
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AIU Faculty of Fine Arts Workshop 3

 :

.

Rolling : compression process to

reduce the thickness of a slab by a pair
of rolls.

:


.

Forging : compression process

performing between a set of opposing
dies.

:
) (
.

Extrusion : compression process to

squeeze the metal flow through a die
opening.

:



.
)
( F

Drawing : pulling a wire or bar through

a die opening.

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AIU Faculty of Fine Arts Workshop 3

Sheet formation

: / /

.

Bending : straining of a metal sheet to

form an angle bend.

:

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Drawing : forming a sheet into a

hollow or concave shape.

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/

Shearing : not a forming process as

much as a cutting process.

. /

By beveling the punch or the die surfaces, as

shown in the Figure, the total shearing force
will be reduced. This geometry is particularly
suitable for shearing thick blanks.

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AIU Faculty of Fine Arts Workshop 3

Friction in Metal Forming

friction is undesirable In metal

forming processes, because of :

Metal flow is retarded
Forces and power are increased
Wears tooling faster
Metalworking lubricants are applied

.
:

to tool work interface in many

forming operations to reduce
harmful effects of friction .
Benefits:
Reduced sticking, forces, tool
wear
Better surface finish
Removes heat from the tooling

Special Forming Methods

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AIU Faculty of Fine Arts Workshop 3

Rubber Froming :
one of the dies is made of
flexible material, such as a
rubber.

:


.
:
.

Fluid Forming : The pressure over the rubber membrane is

controlled throughout the forming cycle

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:

This procedure allows close

control during forming to
prevent wrinkling or tearing.
Explosive energy used for metal
forming
Sheet-metal blank is clamped over a
die
Assembly is immersed in a tank with
water
Rapid conversion of explosive charge
into gas generates a shock wave. The
pressure of this wave is sufficient to
form sheet metals

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AIU Faculty of Fine Arts Workshop 3

 :

) (Blanking
) (




)(Ironing

) (Doming /Forging/
) (Necking /Rolls/
/ (Seaming) /
.
:

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AIU Faculty of Fine Arts Workshop 3