Hot Forming, Cold Forming and Warm Forming

Metal forming processes may be carried out in hot as well as in cold state.
Temperature
of re-crystallization is the boundary between the two.
Hot forming or hot working is defined as forming at temperatures above the recrystallization temperature of the metal. In fact the actual temperatures are much
higher than the recrystallization temperature. High temperatures reduce the flow
stress of metals, which results in low deforming forces.
Cold forming or cold working refers to forming at temperatures below the recrystallization
temperature of the metal. The strain hardening during the process improves the
mechanical
properties of the product. Also close dimensional tolerances can be obtained in cold
forming.

Fig.

Effect of temperature on the yield strength

Advantages of hot forming

(i) At high temperatures, the metals become soft, its yield strength decreases (Fig.)
and hence low forces are required for forming. This reduces the cost of equipment
needed for the process.
(ii) Metals are more ductile at higher temperatures and their formability in hot state
is higher than in cold state. Therefore, large deformations may be given in hot
working.
(iii) The casting defects in ingots like internal shrinkage cavities (not those in
contact with atmosphere) and blow holes get welded during hot working. The
structure becomes more homogeneous resulting in better mechanical properties.
(iv) Due to low flow stresses at high temperatures, very large components may be
made by plastic deformation.
Disadvantages of hot working
(i) The products have low surface quality due to oxidation of surface layer.

(ii) The components formed have low dimensional accuracy.

(iii) There is little improvement in mechanical properties.
(iv) The forming tools also get heated up due to contact with hot metal and wear of
tools is rapid.
Advantages of cold forming
(i) Good surface finish of the product.
(ii) High dimensional accuracy.
(iii) Superior mechanical properties, e.g. hardness and strength increase due to
strain hardening.
(iv) Strain hardening may eliminate the surface hardening heat treatment required
in some components such as cold rolled gears.
(v) The material develops anisotropy which may be used to advantage in
subsequent forming processes. For instance, the anisotropy developed in cold rolled
sheet metal helps in getting deeper draws.
Disadvantages of cold forming
(i) High loads on the equipment require it to have high strength and rigidity. This
increases the cost of machines.
(ii) With strain hardening the material becomes less ductile.