Teknologi Manufaktur

(TPS-1116A)

Tatap Maya-6 Minggu ke-6

Selasa, 6 April 2021
Jam 10.00-12.30

Prodi Teknologi Pengolahan Sawit (D-3)

INSTITUT TEKNOLOGI SAINS BANDUNG
(ITSB) 2021
Bagian-2
Fundamentals of Metal
Forming

2
 FUNDAMENTALS OF METAL
FORMING
1. Overview of Metal Forming
2. Material Behavior in Metal
Forming
3. Temperature in Metal Forming

Manufacturing Processes
Prof Simin Nasseri
 Metal Forming
Large group of manufacturing processes
in which plastic deformation is used to
change the shape of metal workpieces

 The tool, usually called a

die, applies stresses that
exceed the yield strength of
the metal

 The metal takes a shape

determined by the geometry
of the die
Manufacturing Processes
Prof Simin Nasseri
 Stresses in Metal Forming

 Stresses to plastically deform the metal are usually

compressive
 Examples: rolling, forging, extrusion
 However, some forming processes
 Stretch the metal (tensile stresses)
 Others bend the metal (tensile and compressive)
 Still others apply shear stresses
Manufacturing Processes
Prof Simin Nasseri
 Material Properties in Metal Forming
 Desirable material properties:
 Low yield strength
 High ductility

These properties are affected by temperature:

Ductility increases and yield strength decreases
when work temperature is raised

T Ductility Yield Strength

Other factors:
Strain rate and friction

Manufacturing Processes
Prof Simin Nasseri
 Basic Types of Deformation Processes
1. Bulk deformation
 Rolling
 Forging
 Extrusion
 Wire and bar drawing
2. Sheet metalworking
 Bending
 Deep drawing
 Cutting
 Miscellaneous processes

Manufacturing Processes
Prof Simin Nasseri
Bulk Deformation
 Bulk Deformation Processes
 Characterized by significant deformations
and massive shape changes

 "Bulk" refers to workparts with relatively

low surface area-to-volume ratios

 Starting work shapes include cylindrical billets and

rectangular bars

Manufacturing Processes
Prof Simin Nasseri
 Rolling

The slab is heated in a furnace and

rolled between powered rollers until
the plate is made with desirable
thickness.

Figure 18.2 Basic bulk

deformation processes: (a) rolling

Manufacturing Processes
Prof Simin Nasseri
 Forging
Forging is the process of forming the metal by impacting
and/or squeezing a preheated part between two halves of
a die. A succession of dies may be needed to achieve the
final shape.

Figure 18.2 Basic bulk deformation

processes: (b) forging
Manufacturing Processes
Prof Simin Nasseri
 Extrusion
Billets are preheated and forced by a ram through one or more dies
to achieve the desired cross-section. The product is long in relation
to its cross-sectional dimensions and has a cross section other than
that of rod and bar and pipe and tube.

Aluminum
part

Figure 18.2 Basic

bulk deformation
processes: (c)
extrusion

Manufacturing Processes
Prof Simin Nasseri
 Wire and Bar Drawing
Drawing is an operation in which
the cross-section of solid rod, wire
or tubing is reduced or changed in
shape by pulling it through a die.

Figure 18.2 Basic bulk

deformation processes:
(d) drawing

Manufacturing Processes
Prof Simin Nasseri
Sheet Metal
Working
 Sheet Metalworking
 Forming and related operations performed
on metal sheets, strips, and coils
 High surface area-to-volume ratio of starting
metal, which distinguishes these from bulk
deformation

 Often called pressworking because presses

perform these operations
 Parts are called stampings
 Usual tooling: punch and die

Manufacturing Processes
Prof Simin Nasseri
 Sheet Metal Bending
Straining of a metal sheet or
plate to take an angle.

Figure 18.3 Basic sheet

metalworking operations: (a)
bending

Manufacturing Processes
Prof Simin Nasseri
 Deep Drawing
Forming of a flat metal sheet into
a hollow or concave shape, by
stretching the metal.

Figure 18.3 Basic sheet metalworking operations: (b) drawing

Manufacturing Processes
Prof Simin Nasseri
 Shearing of Sheet Metal

Shearing operation which cuts

the work by using a punch and
die.

Figure 18.3 Basic sheet metalworking operations: (c) shearing

Manufacturing Processes
Prof Simin Nasseri
Temperature in Metal Forming
 Temperature in Metal Forming
 For any metal, K and n in the flow curve
depend on temperature
  K n
 Both strength (K) and strain hardening
(n) are reduced at higher temperatures
 In addition, ductility is increased at higher
temperatures
T K n

Manufacturing Processes
Prof Simin Nasseri
 Temperature in Metal Forming
 Any deformation operation can be accomplished with
lower forces and power at elevated temperature

 Three temperature ranges in metal forming:

 Cold working

 Warm working

 Hot working

Manufacturing Processes
Prof Simin Nasseri
 Temperature in Metal Forming

Cold working refers to plastic

deformation that occurs usually, but
not necessarily, at room temperature.

Warm working: as the name implies,

is carried out at intermediate
temperatures. It is a compromise
between cold and hot working.

Hot working refers to plastic

deformation carried out above the
recrystallization temperature.

Manufacturing Processes
Prof Simin Nasseri
 Temperature in Metal Forming

Increasing temperature

Melting temperature

Room temperature 0.3 Tm 0.5 Tm Tm Above Tm

Recrystallization
Warm Working
Cold working

Hot working

Casting
Manufacturing Processes
Prof Simin Nasseri
 Cold Working
 Performed at room temperature or
slightly above
 Cold Forming is the primary
manufacturing operation of the
fastener industry.

 Many cold forming processes are

important mass production operations

 Minimum or no machining usually

required
 These operations are near net
shape or net shape processes

Manufacturing Processes
Prof Simin Nasseri
 Advantages of Cold Forming
 Better accuracy, closer tolerances

 Better surface finish

 Strain hardening increases

strength and hardness

 Grain flow during deformation can

cause desirable directional
properties in product

Cold forming can make tiny, complex

 No heating of work required
precision parts in one machining
step. Tolerances of 0.0005 in. are
possible.

Manufacturing Processes
Prof Simin Nasseri
 Disadvantages of Cold Forming
 Higher forces and power required in the
deformation operation
 Surfaces of starting workpiece must be free
of scale and dirt (Scale=a usually black scaly coating of oxide
forming on the surface of a metal (as iron) when it is heated for processing)

 Ductility and strain hardening limit the

amount of forming that can be done
 In some cases, metal must be annealed to allow
further deformation
 In other cases, metal is simply not ductile enough
to be cold worked
Annealing: a heat treatment that alters the microstructure of a material causing
changes in properties such as strength and hardness

Manufacturing Processes
Prof Simin Nasseri
 Warm Working
 Performed at temperatures above room
temperature but below recrystallization
temperature

 Dividing line between cold working and warm working

often expressed in terms of melting point:
 0.3Tm,
where Tm = melting point (absolute temperature) for
metal

Manufacturing Processes
Prof Simin Nasseri
 Advantages of Warm Working
 Lower forces and power than in cold
working

 More complex work geometries possible

 Need for annealing may be reduced or

eliminated

Manufacturing Processes
Prof Simin Nasseri
 Hot Working
 Deformation at temperatures above the
recrystallization temperature

 Recrystallization temperature = about

one-half of melting point on absolute scale
 In practice, hot working usually
performed somewhat above 0.5Tm
 Metal continues to soften as temperature
increases above 0.5Tm, enhancing
advantage of hot working above this level

Manufacturing Processes
Prof Simin Nasseri
 Why Hot Working?
Capability for substantial plastic deformation
of the metal - far more than possible with
cold working or warm working
 Why?
 Strength coefficient (K) is substantially
less than at room temperature
 Strain hardening exponent (n) is zero
(theoretically)
 Ductility is significantly increased

Manufacturing Processes
Prof Simin Nasseri
 Advantages of Hot Working
 Workpart shape can be significantly
altered
 Lower forces and power required
 Metals that usually fracture in cold
working can be hot formed
 Strength properties of product are
generally isotropic
 No strengthening of part occurs from
work hardening
 Advantageous in cases when part
is to be subsequently processed by
cold forming

Manufacturing Processes
Prof Simin Nasseri
 Disadvantages of Hot Working
 Lower dimensional accuracy

 Higher total energy required (due to the

thermal energy to heat the workpiece)

 Work surface oxidation (scale), poorer

surface finish

 Shorter tool life

Manufacturing Processes
Prof Simin Nasseri