Module SM1: Forming Technology

Module SM1: Forming Technology
Part SM1-2: Bulk Forming
Lecture 1: Introduction to the Technology of Metal

Forming
2020-21
Prof. Dr.-Ing. habil. Sami Chatti
Content of the Course
1 Introduction to the technology of metal forming
2 Rolling
3 Forging
4 Cold forging
5 Bar extrusion
2020-21 Sami Chatti BF L01 Introduction to Metal Forming 1.2
1
DL interactive
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2
DL interactive – Test
Question: Do you know how to classify forming processes?
Answer options: 0,9
0,8
A) Yes, I know 0,7
0,6
B) No, I don't know 0,5
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C) I am not sure 0,3
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Structure
L1 – Introduction to the Technology of Metal Forming
Introduction
History of forming technology
Current example applications
Classification of forming processes
Techno-economic aspects
3
Structure
Introduction
Classification of Manufacturing Processes

according to DIN 8580
Create Maintain Reduce Increase form

form form form
Form alteration
2. 3. 4.
Forming Cutting Joining
1. 6. 5.
Moulding Change of material properties Coating
Displacement Elimination Introduction

of material of material of material
particles particles particles
4
Manufacturing Possibilities of a Bolt
1. By casting 2. Partial upsetting or extrusion (forming)

( moulding )
Finished part
Small initial Large initial

cross-section cross-section
(material is pressed
through a nozzle)
3. By turning 4. By welding ( joining )

( cutting )
Waste
material
Structure
Introduction
10
5
History of Forming Technology I
Antique: Bending gold and silver, embossing coins, forging (hammering) objects
of all kinds "Disc of Nebra"
Bronze with gold,
Egyptian gold forger around 1600 BC
around 5000 BC (found 1999 in
Nebra, Germany)
800 BC: Early Iron Age in Central Europe. Due to the higher hardness and
strength of the iron it replaced the bronze in many areas.
Middle Ages: First forging machines, screw presses and drop hammers
15th - 16th century: Rolling of tin and lead sheets, spinning
Forging plant (middle age) Rolling plant (1615) Spinning plant

11
History of Forming Technology II
Industrialisation:
18th cent.:Thanks discovering of the steam-engine in 1712, construction of
forging machines, forging of larger workpieces, rolling of iron sheets
Extrusion of lead and non-ferrous metals
1850: First sheet metal working machine
1870: Double-acting deep drawing press
1950: Extrusion of steel
Rolling plant, 1888 Ford T-Model (first serial production in 1914)
Cylinder capacity: 2900 ccm
Power: 22.5 PS (horse power)
(1)
12
6
Structure
Introduction
13
Examples Automotive Industry

Components of a Body of an S-Class
4-cylinder in-line engine
(1) (3)
Rim manufacturing
Light metal wheels
(2)
(4)
Source: (1) www.kfz-tech.de , (2) www.otto-fuchs.com , (3) Daimler (4) BBS International GmbH
14
7
Examples Aerospace Industry
ARIANE – Booster (EADS) Fuel tank bottom
(1)
Air inlet on a jet engine
(3)
Airplane wing
Source: (1) www.wissenschaft-online.de , (2) Rolls Royce, Film: WDR, (3) Leifeld Metal Spinning, www.thefabricator.com
15
Examples Medicine
Artificial knee joint

Artificial hip joint
(1)
(3)
(2)
Manufacturing by forming (forging) and subsequent machining of the joint surfaces which
are then joined with plastic parts.
Source: (1) www.missioklinik.de , (2) www.uni-erfurt.de , (3) www.vitanet.de
16
8
DL interactive – Electrical Conductivity
Question: Which of the following materials is the most conductive?
1
Answer options: 0,9
0,8
A) Stainless steel 0,7
0,6
B) Copper 0,5
0,4
C) BSCCO 0,3
0,2
0,1
D) Brass
0
A B C D
17
Examples Electronics
Production of Superconductors by the OPIT Method (Oxide-Powder-in-Tube Method)
(100 times higher conductivity than copper (100 kA / cm2 <-> 1 kA / cm2))
Powder in the Isostatic Compacted P. Pull to Single fiber

form (Latex tube) compression in silver tube single fiber
0.2 mm
3 mm
Bring together Pulling the Multiple fiber
to multiple fiber multiple fiber bundle Rolling the multiple bundle to the strip
in silver tube
- Bismut-Strontium-Calcium-Cuprat (BSCCO)
Source: N. Bay, M.S. Nielsen Lyngby, Denmark - High-Temp. Super conducting 110 K (-163°C)
18
9
Structure
Introduction
19
Classification of Forming Processes into

Subgroups according to DIN 8582
Forming
Tensile-
Compressive Tensile Bend Shear
compressive
forming forming forming forming
forming
Bending with straight
Bending with rotary
straight tool motion

Shear forming with
Flange forming
Stretch identing
Metal spinning
Deep drawing
Upset bulging
Free forming
Die forming
Indentation
tool motion
tool motion
Elongation
Expanding
Extrusion
Twisting
Drawing
Rolling
20
10
Compressive Forming:
Impression Die Forging
Initial state Instant state Final state
Upper die
Blank
Lower die
Workpiece
21
Compressive Forming: Forging
Example: Drop forging
www.volme-schmiede.de
Upper die
Workpiece
Lower die
22
11
Tensile-Compressive Forming: Deep Drawing
in the First Draw with Blank Holder
Punch
F
Blank holder FB FB
Blank
Die
23
Tensile-Compressive Forming: Deep Drawing
Example: Deep drawing
www.volkswagen.de
Daimler
Punch
Blankholder
Sheet
Die
24
12
Tensile Forming: Expanding with Rubber Punch
Punch
Rubber
Die
Workpiece
25
Tensile Forming: Tensile Test
26
13
Bend Forming: Tube Folding
Clamping jaw
Bending roll
Bending die
Tube
27
Bend Forming: Tube Bending at OPEL
28
14
Shear Forming: Embossing of Sheet Metal
Components

Punch
FP
Blank holder
FBH
Sheet metal
Counter punch
Die
29
Shear Forming: Sheet Metal Embossing

Operation
YouTube
30
15
Classification of Forming Processes into Sheet
Metal Forming and Bulk Forming
Bulk forming Sheet metal forming
• Rolling / Profile rolling • Die bending / Folding

• Upsetting / Forging • Stretch drawing
• Bar extrusion • Deep drawing
 Many process variants have been developed

from the common methods
31
Definition of Metal Forming
Metal Forming:
Manufacturing of a product through a permanent change of the
shape, whereby the mass and the material connectivity do not
change.
Bulk forming: Sheet forming:

• Forming of components with • Forming of sheet
full and tubular cross sections components
• Intended change of cross • No intended change of
sections sheet thickness
• Usually hot forming • Usually cold forming
32
16
Bulk Forming vs. Sheet Metal Forming
Forming Processes
Bulk forming Sheet metal forming

F2 F1
F1 F2
F2
F3 F1
• Blank balanced in all three directions • Blank in the thickness direction
• Material flow in all directions much smaller
• Often multiaxial compressive stress • Workpiece: hollow body with
states approximately constant wall
• Greater forming forces than sheet thickness
metal forming
• Much older than sheet metal forming • Mostly biaxial stress states:
(forging, rolling) tension-tension or tension-
compression
33
DL interactive – Bulk Forming Production
Question: In which country the bulk forming production is highest?
1
Answer options: 0,9
0,8
A) Germany 0,7
0,6
B) France 0,5
0,4
C) Japan 0,3
0,2
0,1
D) China
0
A B C D E
E) USA, Canada, Mexico ID = sami.chatti@udo.edu

34
17
Production Volume of Bulk Forming
Source: Industrieverband Massivumformung, 2014
Sales volume in Mio. €

Production in 1000 Tons
Sheet metal forming

Bulk forming
Time
Source: Industrieverband Massivumformung, 2013
35
Application Field of Bulk Forming Parts in Germany

• Sectors in which massive formed parts from Germany are used:
– Vehicle construction: approx. 60% of total production
Drive pinion, Eccentric shaft Cardan shaft,

Differential gear Transmission flanges
Source: Hirschvogel
– Mechanical engineering: approx. 20%
Conical bearing Srew Steam turbine

Source: wikipedia Source: MAN Turbo
– Aerospace, Energy, Medical technology, Shipbuilding ...
36
18
Bulk Forming – Extrusion
Example: Cold extrusion Production of spark plug

bodies by cold extrusion
Punch
Workpiece
Die
Counter punch
37
Sheet Metal Forming – Press Hardening
Example: Press hardening Material: 22MnB5

Thickness: 1.75 mm
Oven temperature: 950°C
38
19
Hot forming – Cold forming
According to DIN 8582
Forming after heating - Hot forming
Forming without heating - Cold forming
Forming without change in strength
Forming with temporary change

in strength
Forming with permanent change

in strength
39
Properties of Cold, Warm and Hot Forming
Cold Warm Hot

Advantages Advantages Advantages
• Good dimensional stability • Advantages of cold and hot • Complex product

(low tolerances) forming are exploited geometries possible
• Increased product strength • Higher formability • Good formability
• Higher surface quality • Lower tool stress • Low tool load
• Low material loss Disadvantages • Workpieces with large
Disadvantages • Expensive tools volume and large mass
• High tool load • Tools must withstand both Disadvantages
• Several forming steps high pressures and high • Oxide layers (scale)
required temperatures • Low dimensional
• Intermediate annealing accuracy
may be required
• Low formability
Steel: Room temperature Steel: 750-950oC Steel: 1150-1250oC

Al: Room temperature Al: 200-300°C Al: 450-550°C
40
20
Motion States During the Forming Process
v Wz
Course line
Streamline v Wz
Motion state of a transient forming Motion state of a stationary forming

process (upsetting) process (bar extrusion)
41
Structure
Introduction
42
21
Material Savings by Cold Extrusion
Material: Ck 35
Quantity: 90 pieces/minute
(Hatebur) Material savings: 75%
43
Energy Requirements in Forming and Machining
Component manufactured by forming Component manufactured by machining

50 50
Loss Loss
40 40
Energy requirement in MJ / kg
Energy requirement in MJ / kg
Forming Machining
30 30
Rolling Rolling
20 20
Steel manufacturing Steel manufacturing
10 10
0 0
 28 MJ / kg  45 MJ / kg
44
22
Energy Consumption and Global Warming Gases
Energy consumption
Material Raw materials
(MJ/kg)
Titanium 900 - 940 Ilmenite, Rutile
Aluminium 227 - 342 Bauxite
Silicon 230 - 235 Raw silicon (silicon oxides)
Polyethylene 87 - 115 Raw oil
Steel 20 - 50 Iron, Carbon

Glass 18 - 35 Sand
Iron 20 - 25 Iron ore
Wood 3-7 Forest stand
Source: Vaclav Smil
CO2 100 MJ  5 kg CO2

Methane
Nitrogen oxide
CFC
45
DL interactive – Energy Consumption
Question: After the materials of the car wich part consumes most primary
energy in the manufacturing of a VW Golf III?
1
Answer options:
0,9
0,8
A) Motor
0,7
0,6
B) Gearbox
0,5
0,4
C) Carcass 0,3
0,2
D) Assembly 0,1
0
A B C D E
E) Painting
46
23
Primary Energy Consumption in the
Manufacturing of a Golf III
Motor (3,1 GJ) Gearbox (2,1 GJ)

Plastic parts (1,7 GJ)
Assembly (2,4 GJ)
Painting (10,6 GJ)

Materials (37,6 GJ)
Carcass (1,9 GJ)

Press plant (forming) (0,8 GJ)
Total energy consumption: 60,2 GJ

© Volkswagen
47
Comparison of Costs Forming - Turning
Formed workpiece
Material: Ma 8
Cost in Euro per 200 pieces
Ø20 Ø10 Turning
10 20
Forming
Turned workpiece
Material: 9 SMnPb 2 3
Ø20 Ø10
Number of parts x 1000
10 20
Example cold forming
In mm Workpiece weight Minimal number of workpieces:
<20 g 10.000
20 bis 500 g 5.000
500 g bis 10 kg 1.000
10 bis 50 kg 1.000
48
24
Fibre of a Drive Shaft After Extrusion
Material: 41 Cr 4
Krupp
49
Fibre of Crankshaft
Forged crankshaft
Crankshaft manufactured by
„machining“
50
25
Reachable Accuracy in Forming
Assumption: diameter of the component (nominal dimension range) 120 to 180 mm
Specification of the tolerance range in mm
IT-Tolerance class IT05 IT06 IT07 IT08 IT09 IT10 IT11 IT12 IT13 IT14 IT15 IT16
Manufact. process Dimension 0,018 0,025 0,04 0,063 0,1 0,16 0,25 0,4 0,63 1,0 1,6 2,5
Hot forming Diameter
Cold forming Diameter
Turning Diameter
Milling Thickness
Cylindrical grinding Diameter
Normally reachable
Reachable by special measures
Accuracy of cold forming
Generally achievable Accuracy in the best Accuracy at best

Dimension
accuracy conditions future conditions
Inner diameter [mm] 0,06 0,01 0,005

Outer diameter [mm] 0,15 0,02 0,001
Thickness [mm] 0,3 0,1 0,05
Surface roughness Rmax [µm] 6 2 0,5
According to Kudo
51
Forming Technology and Lightweight

Construction in Transportation Systems
52
26
Appendix: English for Production Engineers
English Français English Français

Moulding/casting Moulage Compressive forming Formage par compression
Forming Formage Tensile forming Formage par traction
Cutting Usinage Bend forming Formage par cintrage
Joining Assemblage Shear forming Formage par cisaillement
Coating Revêtement Impression die forging Matriçage
Bolt Boulon Deep drawing Emboutissage profond
Upsetting Refoulement Sheet metal forming Formage de tôles
Welding Soudage Bulk forming Formage massif
53
27

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Module SM1: Forming Technology

Part SM1-2: Bulk Forming

Lecture 1: Introduction to the Technology of Metal

Prof. Dr.-Ing. habil. Sami Chatti

Content of the Course

1 Introduction to the technology of metal forming

2020-21 Sami Chatti BF L01 Introduction to Metal Forming 1.2

Live voting during the lecture

Participation via smartphone or laptop

1. Apps for iOS, Android, Windows, MacOS:

2. Browser-based voting form:

Login ID: sami.chatti@udo.edu

2020-21 Sami Chatti BF L01 Introduction to Metal Forming 1.3

1. Install software or open browser-based form

Question: Do you know how to classify forming processes?

Answer options: 0,9

A) Yes, I know 0,7

B) No, I don't know 0,5

C) I am not sure 0,3

2020-21 Sami Chatti BF L01 Introduction to Metal Forming 1.5

L1 – Introduction to the Technology of Metal Forming

History of forming technology

Current example applications

Classification of forming processes

2020-21 Sami Chatti BF L01 Introduction to Metal Forming 1.6

L1 – Introduction to the Technology of Metal Forming

History of forming technology

Current example applications

Classification of forming processes

2020-21 Sami Chatti BF L01 Introduction to Metal Forming 1.7

Classification of Manufacturing Processes

Create Maintain Reduce Increase form

Displacement Elimination Introduction

2020-21 Sami Chatti BF L01 Introduction to Metal Forming 1.8

1. By casting 2. Partial upsetting or extrusion (forming)

Small initial Large initial

3. By turning 4. By welding ( joining )

2020-21 Sami Chatti BF L01 Introduction to Metal Forming 1.9

L1 – Introduction to the Technology of Metal Forming

History of forming technology

Current example applications

Classification of forming processes

2020-21 Sami Chatti BF L01 Introduction to Metal Forming 1.10

Forging plant (middle age) Rolling plant (1615) Spinning plant

History of Forming Technology II

2020-21 Sami Chatti BF L01 Introduction to Metal Forming 1.12

L1 – Introduction to the Technology of Metal Forming

History of forming technology

Current example applications

Classification of forming processes

2020-21 Sami Chatti BF L01 Introduction to Metal Forming 1.13

Examples Automotive Industry

Light metal wheels

Air inlet on a jet engine

Artificial knee joint

Question: Which of the following materials is the most conductive?

A) Stainless steel 0,7

2020-21 Sami Chatti BF L01 Introduction to Metal Forming 1.17

Powder in the Isostatic Compacted P. Pull to Single fiber

L1 – Introduction to the Technology of Metal Forming

History of forming technology

Current example applications

Classification of forming processes