Mapúa University

School of Mechanical and Manufacturing Engineering

Written Report on
METAL FORMING PROCESS

Industrial Processes
ME148 – C1

Submitted by:
BADIOLA, John Remigio W.
BALTAZAR, Jared Elias G.
BAÑEZ, Marielle Louise O.
Lunar, Menric G

Submitted to:
Engr. Jaime Blanco
Instructor
INTRODUCTION
What is Metal Forming?

Metal forming is a manufacturing process in which forces are applied on raw material
such that stresses induced in the material are greater than yield stress and less than ultimate
stress. The material experiences plastic deformation to change the shape of the component and
converted to the desired shape of the component.

Forming process can be broadly classified into two types as cold working and hot working.

PROCESSES
Cold Working

Deforming the material at a temperature below the recrystallization temperature of the

work metal is called cold working. In cold working process, strength and hardness increases due
strain hardening, but ductility decreases. If cold working is higher than certain limits, the metal
will fracture before reaching the desired shape and size. Usually cold working operations are
performed in many steps with intermediate annealing operation.
Advantages

 closer tolerances can be achieved

 good surface finish
 because of strain hardening, higher strength and hardness is seen in part
 grain flow during deformation provides the opportunity for desirable directional
properties
 since no heating of the work is involved, furnace, fuel, electricity costs are minimized
 Machining requirements are minimum resulting in possibility of near net shaped forming.

Disadvantages

 higher forces and power are required

 strain hardening of the work metal limit the amount of forming that can be done
 sometimes cold forming-annealing-cold forming cycle should be followed
 the work piece is not ductile enough to be cold worked.

Hot Working

Deforming the material at a temperature higher or equal to the recrystallization temperature of

the work metal is called hot working. In hot working, refinement of grain size occurs, thus,
improving mechanical properties. This requires much less force for deformation, but the finally
formed surface finish and dimensional accuracy are not good. There is no work hardening.

Advantages

 significant plastic deformation can be given to the sample

 significant change in workpiece shape
 lower forces are required
 materials with premature failure can be hot formed
 absence of strengthening due to work hardening

Disadvantages

 shorter tool life

 poor surface finish
 lower dimensional accuracy
 sample surface oxidation
 BULK FORMING

It is a severe deformation process resulting in massive shape change. The surface area-to-volume
of the work is relatively small. Mostly done in hot working conditions.

ROLLING

In this process, the workpiece in the form of slab or plate is compressed between two rotating
rolls in the thickness direction, so that the thickness is reduced. The rotating rolls draw the slab
into the gap and compresses it. The final product is in the form of sheet.

FORGING
The workpiece is compressed between two dies containing shaped contours. The die shapes are
imparted into the final part.

EXTRUSION
In this, the workpiece is compressed or pushed into the die opening to take the shape of the die
hole as its cross section.

WIRE OR ROD DRAWING

Similar to extrusion, except that the workpiece is pulled through the die opening to take the
cross-section.

SHEET FORMING

Sheet metal forming involves forming and cutting operations performed on metal sheets, strips,
and coils. The surface area-to-volume ratio of the starting metal is relatively high. Tools include
punch, die that are used to deform the sheets.

BENDING
In this, the sheet material is strained by punch to give a bend shape (angle shape) usually in a
straight axis.

DEEP (OR CUP) DRAWING

In this operation, forming of a flat metal sheet into a hollow or concave shape like a cup, is
performed by stretching the metal in some regions. A blank-holder is used to clamp the blank on
the die, while the punch pushes into the sheet metal. The sheet is drawn into the die hole taking
the shape of the cavity.

SHEARING
This is nothing but cutting of sheets by shearing action.
MACHINES AND EQUIPMENTS USED IN METAL FORMING

 Rolling Mills
Rolling mills are machines that shape metal by passing it through two rolls. They are
used to flatten and reduce metal to a sheet or plate.

 Forging Machine
Forging machines (hot forming) use compressive force and a high workpiece temperature
to shape metal by plastic deformation. A type of hot forming, hot forging involves the
plastic deformation of a metal at a temperature and strain rate where recrystallization and
deformation occur simultaneously. This prevents strain hardening, which can reduce
ductility and contribute to brittle failure and structural fatigue.
 Extrusion Machine
Extrusion machine is used by forcing a work piece, of a certain length and cross section,
to flow through a die of a smaller cross sectional area, thus forming the work to the new
cross section

 Drawbenches and Drawing Machines

Drawbenches and drawing machines are use tensile forces to reduce the size of metal
sheets, wire, tubes and rods by drawing metal strips through a drawplate or dies.
 Thread Rolling Machines
Thread rolling machines generate threads by displacing and flowing metal into a thread
shape.

 Shearing Machines (sheet metal)

Shearing machines (sheet metal) use a shearing or scissor-like action to cut metal into
sheets or strips.
 Press Brakes
Press brakes are metal forming machines used to bend and fold sheet and plate metal by
pressing it between tooling referred to as a punch and a die.

 Roll Forming Machines

Roll forming machines bend metal sheet into channels and other cross-sectional shapes.
They use paired rollers called roll stations to form metal parts with long lengths, often in
large quantities. Roll forming equipment that is used to shape steel can fabricate parts
with greater strength-to-weight ratios than can be obtained via alternative methods.
  Riveters and Riveting Machines
Riveters and riveting machines insert fasteners through aligned holes in parts to be
joined, then press or hammer them from the insertion side to provide the second retaining
head.

Maintenance
 Lubrication of moving parts
 Proper Alignment of components to prevent inaccurate production results
 Cleanliness

Safety Management

Every tool can be deemed hazardous to those who are careless. As a professional worker, it is a
common practice to wear PPE within the confines of the metal fabrication plant.

Safety Issues in Metal Fab Industry

 Lack of guards and protection (PPE)

 Insufficient or inconsistent training
 Personnel’s state of mind
Waste Management and Disposal

 Metal fabrication plants have less waste compared to other types fabrication plants. If
there is, it would mostly be metal shavings and metal dust particles, which can be
dangerous if it made contact with the personnel’s eyes or enter their body.

 It is mandatory to properly dispose of these hazardous wastes in order to prevent injury

and other complications to the people inside and outside the fabrication plant.

References:
 http://www.iitg.ac.in/engfac/ganu/public_html/Metal%20forming%20processes_full.pdf
 https://slideplayer.com/slide/5802681/19/images/5/OVERVIEW+OF+METAL+FORMI
NG.jpg
 https://slideplayer.com/slide/5802681/
 https://safestart.com/news/4-major-safety-issues-metal-fabrication-industry/