Professional Documents
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FORMING
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Cold Working
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Advantages of Cold Forming
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Disadvantages of Cold Forming
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Warm Working
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Advantages and Disadvantages
of Warm Working
▪ Advantages
▪ Lower forces and power than in cold working
▪ More intricate work geometries possible
▪ Need for annealing may be reduced or eliminated
▪ Disadvantage
▪ Workpiece must be heated
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Hot Working
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Why Hot Working?
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Advantages of Hot Working
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Disadvantages of Hot Working
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Bulk Deformation
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Four Basic Bulk Deformation
Processes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Rolling
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Types of Rolling
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Flat Rolling Terminology
Diagram of Flat Rolling
▪ Side view of flat rolling, indicating
▪ Draft = amount of thickness before and after thicknesses, work
reduction: velocities, angle of contact with rolls,
and other features
d = t o −t f
▪ Reduction = draft expressed
as a fraction of starting stock
thickness:
d
r =
to
where d = draft; to = starting
thickness; tf = final thickness,
and r = reduction
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Shape Rolling
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Rolling Mill Configurations
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Rolling Mill Configurations
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Other Deformation Processes
Related to Rolling
▪ Thread rolling
▪ Ring rolling
▪ Gear rolling
▪ Roll piercing
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Thread Rolling
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Ring Rolling
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Ring Rolling
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Roll Piercing (Mannesmann
Process)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Forging
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Classification of Forging
Operations
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Types of Forging Operations
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Types of Forging Operations
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Open-Die Forging
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Open-Die Forging with No
Friction
▪ If no friction occurs between work and die surfaces,
then homogeneous deformation occurs, so that radial
flow is uniform throughout workpart height and true
strain is given by
ho
= ln
h
where ho= starting height; and h = height at some
point during compression
▪ At h = final value hf, true strain reaches maximum
value
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Open-Die Forging with No Friction
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Open-Die Forging with Friction
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Open-Die Forging with Friction
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Impression-Die Forging
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Impression-Die Forging
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Impression-Die Forging Practice
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Advantages and Limitations of
Impression-Die Forging
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Flashless Forging
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Forging Hammers
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Upsetting and Heading
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Upset Forging
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Heading (Upset Forging)
▪ (a) Heading a nail using open dies, (b) round head formed
by punch, (c) and (d) two head styles for screws formed by
die, (e) carriage bolt head formed by punch and die
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Swaging
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Swaging and Radial Forging
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Extrusion
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Comments on Direct Extrusion
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Hollow and Semi-Hollow Shapes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Indirect Extrusion
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Comments on Indirect Extrusion
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Advantages of Extrusion
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Hot vs. Cold Extrusion
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Extrusion Ratio
Ao
rx =
Af
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Comments on Die Angle
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Shape of Extrusion Die Orifice
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
13-03-2023
Complex Cross Section
Extruded cross
section for a heat
sink (courtesy of
Aluminum
Company of
America)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Wire and Bar Drawing
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Wire and Bar Drawing
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Area Reduction in Drawing
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Wire Drawing vs. Bar Drawing
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Drawing Practice and Products
▪ Drawing practice:
▪ Usually performed as cold working
▪ Most frequently used for round cross sections
▪ Products:
▪ Wire: electrical wire; wire stock for fences, coat
hangers, and shopping carts
▪ Rod stock for nails, screws, rivets, and springs
▪ Bar stock: metal bars for machining, forging, and
other processes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Bar Drawing Bench
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Skiped
Wire Drawing
▪ Continuous drawing machines consisting of multiple draw dies (typically 4 to 12) separated
by accumulating drums
▪ Each drum (capstan) provides proper force to draw wire stock through upstream die
▪ Each die provides a small reduction, so desired total reduction is achieved by the
series of dies
▪ Annealing sometimes required between dies to relieve work hardening
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Features of a Draw Die
▪ Entry region - funnels lubricant into the die to prevent scoring of work and die
▪ Approach - cone-shaped region where drawing occurs
▪ Bearing surface - determines final stock size
▪ Back relief - exit zone - provided with a back relief angle (half-angle) of about 30
▪ Die materials: tool steels or cemented carbides
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Preparation of Work for Drawing
▪ Annealing – to increase ductility of stock
▪ Cleaning - to prevent damage to work surface and
draw die
▪ Pointing – to reduce diameter of starting end to allow
insertion through draw die
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
SHEET METALWORKING
1. Cutting Operations
2. Bending Operations
3. Drawing
4. Other Sheet Metal Forming Operations
5. Dies and Presses for Sheet Metal Processes
6. Sheet Metal Operations Not Performed on Presses
7. Bending of Tube Stock
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Sheet Metalworking Definition
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Sheet and Plate Metal Products
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Advantages of Sheet Metal Parts
▪ High strength
▪ Good dimensional accuracy
▪ Good surface finish
▪ Relatively low cost
▪ Economical mass production for large quantities
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Sheet Metalworking Terminology
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Basic Types of
Sheet Metal Processes
1. Cutting
▪ Shearing to separate large sheets
▪ Blanking to cut part perimeters out of sheet metal
▪ Punching to make holes in sheet metal
2. Bending
▪ Straining sheet around a straight axis
3. Drawing
▪ Forming of sheet into convex or concave shapes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Sheet Metal Cutting
▪ (1) Just before punch contacts work; (2) punch pushes into
work, causing plastic deformation; (3) punch penetrates into
work causing a smooth cut surface; and (4) fracture is
initiated at opposing cutting edges to separate the sheet
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Shearing, Blanking, and
Punching
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Shearing Operation
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Blanking and Punching
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Clearance in Sheet Metal Cutting
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Clearance in Sheet Metal Cutting
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Sheet Metal Groups Allowances
Metal group a
1100S and 5052S aluminum alloys, all 0.045
tempers
2024ST and 6061ST aluminum alloys; brass, 0.060
soft cold rolled steel, soft stainless steel
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Punch and Die Sizes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Punch and Die Sizes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Angular Clearance
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Cutting Forces
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Sheet Metal Bending
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Types of Sheet Metal Bending
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
V-Bending
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Edge Bending
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Stretching during Bending
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Bend Allowance Formula
α
Ab = 2π ( R + K bat )
360
where Ab = bend allowance; = bend angle; R =
bend radius; t = stock thickness; and Kba is factor to
estimate stretching
▪ If R < 2t, Kba = 0.33
▪ If R 2t, Kba = 0.50
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Springback
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Springback
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Bending Force
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Die Opening Dimension
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Drawing
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Deep Drawing of Cup
▪ (a) Drawing of
cup-shaped part: (1)
before punch contacts
work, (2) near end of
stroke
▪ (b) Starting blank and
drawn part
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Clearance in Drawing
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Tests of Drawing Feasibility
▪ Drawing ratio
▪ Reduction
▪ Thickness-to-diameter ratio
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Drawing Ratio DR
Db
DR =
Dp
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Reduction r
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Thickness-to-Diameter Ratio t/Db
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Blank Size Determination
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
A drawing operation is performed on 3.2 mm stock. The part is a cylindrical cup with
inside height = 40 mm and inside diameter = 60 mm. Assume the corner radius on the
punch is zero.
(a) Find the required starting blank size Db.
(b) (b) Is the drawing operation feasible?
Solution:
(a) Use surface area computation, assuming thickness t remains constant.
Cup area = wall area + base area = Dph + Dp2/4 = (60)(40) + 0.25(60)2 = 10,367
mm2
Blank area = Db2/4 = 0.7855Db2
Setting blank area = cup area: 0.7855Db2 = 10,367
Db2 = 10,367/0.7855 = 13,198
Db = 114.9 mm
(b) Test for feasibility: DR = Db/Dp = 114.9/60 = 1.915; t/Db = 3.2/114.9 = 0.0279 =
2.79%. These criteria values indicate that the operation is feasible; however, with a
punch radius
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Shapes other than Cylindrical
Cups
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Other Sheet Metal Forming on
Presses
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Ironing
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Embossing
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Guerin Process
▪ (1) Before
and (2) after
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Advantages of Guerin Process
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Dies for Sheet Metal Processes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Punch and Die Components
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Stamping Press
▪ Components of a
typical mechanical
drive stamping
press
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Types of Stamping Press Frame
▪ Gap frame
▪ Configuration of the letter C and often referred to
as a C-frame
▪ Straight-sided frame
▪ Box-like construction for higher tonnage
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Gap Frame
Press
▪ Gap frame press for
sheet metalworking
(photo courtesy of BCN
Technology Services)
▪ Capacity = 1350 kN
(150 tons)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Press Brake
▪ Press brake
(photo courtesy
of Strippit, Inc.)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
CNC Turret Press
▪ Computer
numerical
control turret
press (photo
courtesy of
Strippit, Inc.)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Straight-sided frame
press for sheet
metalworking (photo
courtesy of BCN
Technology Services)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
CNC Turret Press Parts
▪ Collection of
sheet metal
parts produced
on a turret press,
showing variety
of hole shapes
possible (photo
courtesy of
Strippit Inc.)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Power and Drive Systems
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Operations Not Performed on
Presses
▪ Stretch forming
▪ Roll bending and forming
▪ Spinning
▪ High-energy-rate forming processes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Stretch Forming
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Roll Bending
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Roll Forming
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Spinning
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Conventional Spinning
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
High-Energy-Rate Forming
(HERF)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Explosive Forming
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Explosive Forming
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Electromagnetic Forming
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Electromagnetic Forming
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Bending of Tube Stock
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Bending of Tube Stock
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Bending of Tube Stock
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e