Forming and Shaping
Forming: means changing the
shape of an existing solid
body.
Ex. The metal body for a car
(sheet metal forming)
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Shaping: usually involves
molding and casting.
Ex. The white ceramic
insulator for a spark plug of a
car body for a car (clay
molding, drying and firing)
 Metal Forming Processes
• Metal Forming includes a large group of
manufacturing processes in which plastic
deformation is used to change the shape of metal
work-pieces.

• Deformation results from the use of a tool, usually a

die in metal forming, which applies stresses that
exceed the yield strength of the metal.

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 (a) (b) (c) (d) (e) (f) (g) (h)

Hammer forging two connecting rods; (a) bar stock;

after (b) fullering, (c) “rolling”, (d) blocking, (e) finishing,
(f) trimming; (g) the flash; (h) the forging dies.

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 Metal Forming Processes

Sheet Metal-working: Bulk Deformation:

 Also called “Press-working”.  Compressive deformation force.

 Cold working processes.  Significant deformations.

 Use set of punch and die.  Massive shape changes.

 Performed on metal sheets, strips  Starting work shapes include billets

and coils. and rectangular bars.

 Surface area / volume is large.  Surface area / volume is small.

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 Metal Forming Processes

Sheet Bulk
Metalworking Deformation
Surface Surface
Bending Area / Area / Rolling
Volume Volume
operations is large is small
Forging
Shearing
processes Extrusion

Deep or Cup Wire and Bar

drawing drawing
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 Bulk Deformation Processes
Rolling: A compressive deformation process in which the
thickness of slab or plate is reduced by two opposing
tools “rolls”. They rotate to draw the work piece into the
gap between them and squeeze it.

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 Bulk Deformation Processes
Forging: The work-piece is compressed between two
opposing dies so that the die shapes are imparted to work.
It is traditionally hot working process however many types
of forging are performed cold.

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 Bulk Deformation Processes

Extrusion: A compressive deformation process in which

the work metal is forced to flow through a die opening to
produce a desired cross-sectional shape.

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 Bulk Deformation Processes

Drawing: The work metal is being pulled through a die

opening to reduce the diameter of a wire or a bar. See Fig.
Wire Drawing.

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 Examples of Precision
Cold Forged Products

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 Precision Hot Forging of Complex
Shapes

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 Precision Hot Forging of Complex
Shapes

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 Sheet Metalworking Processes

Bending: It involves straining of metal sheet or plate to take

an angle along a (usually) straight axis.

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 Sheet Metalworking Processes
Drawing: (Cup or deep drawing) Forming of a flat metal
sheet into a hollow or concave shape, such as cup, by
stretching the metal. A blank holder is used to hold down
the blank while the punch pushes into the sheet metal.

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 Sheet Metalworking Processes
Shearing: It involves cutting rather than forming of a
metal. A shearing operation cuts the work using a punch
and die.

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 Importance of Metal Forming in
Manufacturing Engineering

• Net Shape or Close to Net Shape

• High Production Rate
• High Profit Margin
• Low Scrap Rate
• Improving Material Properties

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 Applications and Products of Metal
forming in Macro Scale
• Automotive
• Aerospace
• Appliance
• Cookware

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 Current Issues of Metal Forming Industry

• Lack of Experienced Metal Forming Engineer

• Short Product Life Cycle
• New Metallic Materials
• Developing New Hybrid Process
• High Accuracy and Small Feature Products

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 Skills Needed for Metal Forming
Engineering
• Mechanics
• Material Science
• Manufacturing Process
• Design and Control
• Machinery
• Computer Skills
• FEA

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 Students Need

• To know the current and future needs of

metal forming industry.

• To be taught on a series of classes to meet

challenges of current and future metal
forming industry.

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 Homework
• Is metal forming the most cost effective
manufacturing process?
• Why metal forming is the best process for
mass production?
• According to your imagination, what is the
best process to make beverage can?

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