CH 4

CHAPTER 4
METAL DEFORMATION
METAL FORMING
PGS.TS. NGUYỄN NGỌC HÀ 1

1. FUNDAMENTALS OF
METAL FORMING

1.1. METAL FORMING ?
 Large group of manufacturing processes in which
plastic deformation is used to change the shape
of metal workpieces (Phôi gia công)
 The tool, usually called a die (Khuôn), applies
stresses (Ứng suất) that exceed the yield strength (Giới
hạn chảy) of the metal
 The metal takes a shape determined by the
geometry of the die
1.2. STRESSES IN METAL FORMING
Stresses to plastically deform the metal are
usually compressive (Ép)
Examples: rolling (Cán), forging (Rèn), extrusion
(Ép đùn) …
However, some forming processes:

 Stretch (Vuốt, kéo) the metal (tensile stresses)
 Others bend (Uốn) the metal (tensile and
compressive)
 Still others apply shear (Cắt) stresses

1.3. 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
Other factors: Strain rate (Tốc độ biến dạng) and friction
(Ma sát)
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1.4. CLASSIFICATION OF
METAL FORMING PROCESSES
1. Bulk deformation (BD khối)
– Rolling processes
– Forging processes
– Extrusion processes
– Wire and bar drawing (Kéo)
2. Sheet (Tấm) metalworking
– Bending operations
– Deep or cup drawing
– Shearing processes

1.5. 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 (Gia công nguội)
– Warm working
– Hot working

1.5.1. Cold Working
 Performed at room
temperature or slightly
above
 Minimum or no machining
(Gia công cơ) usually required
– These operations are near net
shape or net shape processes

Advantages of Cold Forming
 Better accuracy, closer tolerances (Dung sai)

 Better surface finish
 Strain hardening (Hóa bền biến dạng)  increases
strength and hardness
 Grain flow (Thớ) during deformation can cause
desirable directional (dị hướng) properties in product
 No heating of work required

Disadvantages of Cold Forming
Higher forces and power required for
deformation
Surfaces of starting work must be free of scale
(gỉ) and dirt
Ductility and strain hardening limit the

amount of forming that can be done
• In some cases, metal must be annealed before
further deformation can be accomplished
• In other cases, metal is simply not ductile enough
to be cold worked
1.5.2. Warm Working
Performed at temperatures above room

temperature but below recrystallization (Kết tinh
lại) 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
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

1.5.3. 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
Why Hot Working?
Capability for substantial plastic deformation -
far more than is possible with cold working or
warm working
Why? Ductility is significantly increased

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 (Đẳng hướng)
 No strengthening of part occurs from work
hardening
Disadvantages of Hot Working
Lower dimensional accuracy
Higher total energy required
Work surface oxidation (scale), thus, poorer

surface finish
Shorter tool life

2. BULK DEFORMATION
PROCESSES

BULK DEFORMATION?
Metal forming operations which cause
significant shape change by deformation in
metal parts whose initial form is bulk rather
than sheet
These processes work by stressing metal
sufficiently to cause plastic flow into desired
shape
Four Basic Bulk Deformation Processes
1.Rolling – slab or plate is squeezed between
opposing rolls (Trục cán)
2.Forging – work is squeezed and shaped
between opposing dies
3.Extrusion – work is squeezed through a die
opening (Lỗ khuôn), thereby taking the shape of
the opening
4.Wire and bar drawing – diameter of wire or
bar is reduced by pulling it through a die
opening
2.1. ROLLING
2.1.1. General
Rolling?
Deformation process in which work thickness
is reduced by compressive forces exerted by
two opposing rolls
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Types of Rolling
By geometry of work:
– Flat rolling (Cán phẳng) - used to reduce thickness of a
rectangular cross-section
– Shape rolling (Cán hình) - a square cross-section is formed
into a shape such as an I-beam
By temperature of work:
– Hot Rolling – most common due to the large amount of
deformation required
– Cold rolling – produces finished sheet and plate stock

Rolling Mechanics
 The rolling process is governed by the frictional
force between the rollers and the workpiece. The
frictional force at the entrance side is higher than
that at the exit side. This allows the roller to pull
the workpiece towards the exit end

Material and Process Parameters
Material Parameters:
– Ductility
– Coefficient of friction
– Strength, modulus and Poisson’s ratio
Process Parameters:
– Roller speed
– Power
– Draft
– Lubrication

2.1.2. Rolling Mill Configurations
a) two high b) three high c) four high

d) cluster (Cụm) mill e) tandem (Nối tiếp) rolling mill
2.1.3. Ring Rolling (Cán vòng)
 To make a larger and thinner ring from the

original ring
 Usually a hot rolling process for large rings and
cold rolling for small rings
 Typical applications: bearing races (Vòng đỡ ổ bi),
steel tires, rings for pressure vessel…
2.1.4. Thread Rolling (Cán ren)
 Production of external thread (Ren ngoài)

 Cold rolling
 High and competitive production rate

2.1.5. Roll Piercing (Cán đột)
Hot working process

Production of Seamless thick-wall tubes

2.2. FORGING
2.2.1. General
 Deformation process in which work is compressed
between two dies
 Oldest of the metal forming operations, dating
from about 5000 BC

Classification of Forging Operations
Cold vs. hot forging:
– Hot or warm forging – most common, due to the
significant deformation and the need to reduce
strength and increase ductility of work metal
– Cold forging - advantage is increased strength that
results from strain hardening
Impact vs. press forging:
– Forge hammer (Rèn búa) - applies an impact load
– Forge press (Rèn ép) - applies gradual pressure

Types of Forging Dies
1.Open-die (Khuôn hở) forging - work is compressed
between two flat dies, allowing metal to flow laterally
without constraint
2.Impression-die (Khuôn ép) forging - die surfaces
contain a cavity or impression that is imparted to
workpart, thus constraining metal flow - flash is created
3.Fleshless (Không bavia) forging - workpart is completely
constrained in die and no excess flash is produced
2.1.2. Open-Die Forging
Compression of workpart with cylindrical
cross-section between two flat dies
Deformation operation reduces height and
increases diameter of work
Common names include upsetting or upset
forging (Chồn)
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2.1.3. Impression-Die Forging
Compression of workpart by dies with inverse

of desired part shape
Flash is formed by metal that flows beyond die
cavity into small gap (Khe hở) between die plates
Flash must be later trimmed from part, but it
serves an important function during
compression
Sequence in impression-die forging:
1. just prior to initial contact with raw workpiece,
2. partial compression, and
3. final die closure, causing flash to form in gap
between die plates
2.1.4. Flashless Forging
Compression of work in punch and die tooling

whose cavity does not allow for flash
Starting workpart volume must equal die
cavity volume within very close tolerance
Process control more demanding than
impression-die forging
Best suited to part geometries that are simple
and symmetrical
Often classified as a precision forging process
2.1.5. Principles of forging machines
Forging Hammers (Drop Hammers)
Apply an impact load against workpart - two

types:
– Gravity drop hammers - impact energy from
falling weight of a heavy ram
– Power drop hammers - accelerate the ram by
pressurized air or steam

Forging Hammers (Drop Hammers)
Disadvantage: impact energy transmitted

through anvil into floor of building
Most commonly used for impression-die
forging

Forging Presses
Apply gradual pressure to accomplish
compression operation - types:
– Mechanical presses - converts rotation of drive
motor into linear motion of ram
– Hydraulic (Thủy lực) presses - hydraulic piston actuates

ram
– Screw (Vít) presses - screw mechanism drives ram

Advantages of forging
Advantages compared to machining from solid

stock:
– Higher production rates
– Conservation of metal (less waste)
– Greater strength
– Favorable grain orientation in the metal

Limitations of forging
 Not capable of close tolerances
 Machining often required to achieve

accuracies and features needed, such as
holes, threads, and mating surfaces that fit
with other components

2.3. EXTRUSION (Ép đùn)
2.3.1. General
Compression forming process in which the
work metal is forced to flow through a die
opening to produce a desired cross-sectional
shape
In general, extrusion is used to produce long
parts of uniform cross-sections
General Advantages of Extrusion
 Variety of shapes possible, especially in hot
extrusion
 Grain structure and strength enhanced in cold
and warm extrusion
 Close tolerances possible, especially in cold
extrusion
 In some operations, little or no waste of material
2.3.2. Direct Extrusion
Also called forward extrusion
As ram approaches die opening, a small
portion of billet remains that cannot be forced
through die opening
Starting billet cross section usually round, but
final shape is determined by die opening
(a) Direct extrusion to produce a

hollow or semi-hollow
cross-section;
(b) Hollow
(c) Semi-hollow cross- sections
2.3.3. Indirect Extrusion
Also called backward extrusion and reverse
extrusion
Limitations of indirect extrusion are imposed
by the lower rigidity of hollow ram and
difficulty in supporting extruded product as it
exits die
(a) a solid cross-section and (b) a hollow cross-section

A complex extruded cross-section for a heat sink
(photo courtesy of Aluminum Company of America)

2.4. WIRE AND BAR DRAWING
Cross-section of a bar, rod, or wire is reduced

by pulling it through a die opening
Similar to extrusion except work is pulled
through die in drawing (it is pushed through in
extrusion)

Wire Drawing vs. Bar Drawing
 Difference between bar drawing and wire drawing
is stock size
– Bar drawing - large diameter bar and rod stock
– Wire drawing - small diameter stock - wire sizes down
to 0.03 mm are possible
 Although the mechanics are the same, the

methods, equipment, and even terminology are
different
Drawing Practice
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

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
– Annealing sometimes required between dies
Bar Drawing
Accomplished as a single-draft operation - the

stock is pulled through one die opening
Beginning stock has large diameter and is a
straight cylinder
This necessitates a batch type operation

3. SHEET METAL FORMING
PROCESSES

INTRODUCTION
1.Bending Operations
2.Drawing
3.Cutting Operations
4.Other Sheet Metal Forming Operations
 Cutting and forming operations performed on
relatively thin sheets of metal
 Operations usually performed as cold working
3.1. SHEET METAL BENDING
3.1.1. General
Straining sheet metal around a straight axis to
take a permanent bend
Metal below the neutral axis is compressed, while

metal above the neutral axis is stretched
Metal on neutral axis neither stretched nor compressed
3.3.2. V-Bending (Uốn V)
For low production
Performed on a brake press (Đế ép)
V-dies are simple and inexpensive
 Punch: Chày

3.3.3. Edge Bending (Uốn mép)
For high production
Pressure pad required
Dies are more complicated and costly

3.2. DRAWING (Dập vuốt)
Sheet metal forming to make cup-shaped,

box-shaped, or other complex-curved,
hollow-shaped parts
Sheet metal blank is positioned over die cavity
and then punch pushes metal into opening

3.2. DRAWING
Products: beverage cans, ammunition shells,
automobile body panels
Also known as deep drawing (Dập sâu) (to
distinguish it from wire and bar drawing)

Drawing Without Blank Holder & Ironing

3.3. SHEET CUTTING
Principal operations in press working that cut
sheet metal:
 Shearing
 Blanking
 Punching
 Piercing

3.3.1. Shearing (Cắt)
Sheet metal cutting operation along a straight
line between two cutting edges
Typically used to cut large sheets
Engagement of entire
blade into cutting need
higher forces.
Therefore, inclined
blade is used to reduce
force and to improve
cut- edge

3.3.2. Blanking and Punching (Đột)
Blanking - sheet metal cutting to separate

piece (called a blank) from surrounding stock
(a) Blanking and (b) punching

3.3.2. Blanking and Punching
Punching - similar to blanking except cut piece

is scrap, called a slug

3.4. ROLL BENDING
Large metal sheets and plates are formed into
curved sections using rolls
Plastic deformation but no significant material flow

3.5. SPINNING (Miết/Tiện dựng)
 Metal forming process in which an axially
symmetric part is gradually shaped over a rotating
mandrel using a rounded tool or roller
 Products: Automobile parts, Utensils, Aerospace
parts …
Conventional spinning: (1) setup at start of process; (2)
during spinning; and (3) completion of process

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CHAPTER 4

PGS.TS. NGUYỄN NGỌC HÀ 1

PGS.TS. NGUYỄN NGỌC HÀ 2

However, some forming processes:

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 Better accuracy, closer tolerances (Dung sai)

PGS.TS. NGUYỄN NGỌC HÀ 9

Ductility and strain hardening limit the

Performed at temperatures above room

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PGS.TS. NGUYỄN NGỌC HÀ 15

 Workpart shape can be significantly altered

Higher total energy required

Work surface oxidation (scale), thus, poorer

Shorter tool life

PGS.TS. NGUYỄN NGỌC HÀ 18

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a) two high b) three high c) four high

 To make a larger and thinner ring from the

 Production of external thread (Ren ngoài)

PGS.TS. NGUYỄN NGỌC HÀ 29

Hot working process

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Compression of workpart by dies with inverse

Compression of work in punch and die tooling

Apply an impact load against workpart - two

PGS.TS. NGUYỄN NGỌC HÀ 39

Disadvantage: impact energy transmitted

PGS.TS. NGUYỄN NGỌC HÀ 40

– Hydraulic (Thủy lực) presses - hydraulic piston actuates

– Screw (Vít) presses - screw mechanism drives ram

PGS.TS. NGUYỄN NGỌC HÀ 42

Advantages compared to machining from solid

PGS.TS. NGUYỄN NGỌC HÀ 44

 Not capable of close tolerances

 Machining often required to achieve

PGS.TS. NGUYỄN NGỌC HÀ 45

(a) Direct extrusion to produce a

(a) a solid cross-section and (b) a hollow cross-section

PGS.TS. NGUYỄN NGỌC HÀ 51

Cross-section of a bar, rod, or wire is reduced

PGS.TS. NGUYỄN NGỌC HÀ 52

 Although the mechanics are the same, the

PGS.TS. NGUYỄN NGỌC HÀ 55

Wire: electrical wire; wire stock for fences,

PGS.TS. NGUYỄN NGỌC HÀ 56

Accomplished as a single-draft operation - the

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Metal below the neutral axis is compressed, while

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Sheet metal forming to make cup-shaped,

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