Metal Forming Fundamentals

The Product of desired shape is a major part of the manufacturing process.

1. Consolidate smaller Pieces

a. Welding : To join two pieces of metal or plastic by heating and allowing the
edges to flow together
b. Adhesive : Using a substance to stick objects or materials together
c. Fastener Hardware device that mechanically joins or affixes two or more object
together
2. Machining

Machining is another way and machinery and this can not only apply to Metals
but Woods as well where we're going to take a raw material and we're going to cut it
down into a desired final shape and size by control material removal process. Okay, so
we're starting off with a large piece of material and we're just basically going to whittle
away what we don't want.

3. Casting
a. An object made by pouring molten metal or other material into a mold
b. Nearly any type of material can be cast
c. Any size of casting can be prodced
4. Deformation process
a. Moving the Material to a different location
b. Excellent surface finish
c. Close tolerance

tool or die geometry. tooling is going to produce and control a Metal Flow. here we're
like some kind of a bending operation so we can specify the type of tooling and die geometry
and assess the success or failure of the process often depends upon that

A lubrication is especially true in working with Metals fishing can account for more than
50% of the power supply do a deformation process. So the amount of lubrication that we use can
also that's one of things that we can specify during the process selection.
 The starting temperature and we'll look at some different how working and co-working
processes when material properties are going to vary greatly with temperature. If we heat
something up a lot, okay, it's going to be much easier to bend shape and form and so forth than
it would be if it's totally cold.

The speed of the operation, how fast it's going to be done? So like on this bending
operation here. This could be done quickly or slowly. We can also specify the speed of the
operation. So this speed is going to influence a lubrication Effectiveness amount of force
required and the amount of heat transfer.

And then lastly the amount of deformation, you can't specify how far the object will be
bent twisted or shape. So here we're like a bending operation. This is being bent at a 90-degree
here. We're bending again. Okay, so we can again specify how far the object will be bent twisted
or shaped.

Material properties of the product it is important to know or be able to predict how the
process will alter the material. So some processes may actually make the material stronger give
us a better surface finish other processes may have totally ruined they totally ruin the material.
So again, it's going to be important or predict how the process is going to change that material.
Okay, and to temperature so anytime we do I deformation operation. It's going to generate Heat.
There's going to be some heat generated. And again, it's going to be important to know that so
somewhat can't the process is generated a lot of heat. It may not be readily available. Someone
picks that picks that material up as it's exiting a process and an extremely hot need to know that
we need to know what the process is done to the material as a generated and heat and if so, how
much.

surface finish and precision. depending upon the specific details of the product or the
process.

Another nature of the material flow. So the end result produces a desire geometric shape.
That's what it really all comes down to so if we've got Gears that are going to fit together.
Disadvantages of Hot Working:

1. High Temperatures can produce poor surface finish.

2. Metallurgical structure may not be uniform.
3. Tolerance are poor.
4. Heating and material handling considerations.

Hot Working Processes

1. Rolling
2. Forging
3. Extrusion
4. Hot Drawing

Cold Working

Cold working clod working is like the opposite of hot working. So now we're not heating
the metal up at all. It's done below the recrystallization temperature or at room temperature.

Advantages of Cold Working :

1. No heating required.
2. Better surface finish achieved.
3. Superior dimension control achieved.
4. Better reproducibility and interchangeability.
5. Strength, wear and fatigue properties are improved.
6. Contamination properties are minimized.

Disadvantages of Cold Working

1. Higher forces are required

2. Heavier and more powerful equipment is required.
3. Less ductility is available
4. Metal surface must be clean and scale free before beginning.
5. Strain hardening occurs
6. Undesirable residual stresses may be produced
Cold Working Processes

Squeezing :

 Rolling.
 Cold Forming.
 Riveting.

Bending :

 Angel.
 Roll.
 Roll Forming.

Drawing :

 Wire Drawing.
 Stretch Forming.

Soal dan jawaban:

Sebutkan proses dari Hot workig?

Jawab :
 Rolling
 Forging
 Extrusion
 Hot Drawing

Sebut kan keuntungan dari Cold Working

o No heating required.
o Better surface finish achieved.
o Superior dimension control achieved.
o Better reproducibility and interchangeability.
o Strength, wear and fatigue properties are improved.
o Contamination properties are minimized.