FORMING AND SHAPING
PROCESSES IN
MANUFACTURING TECHNOLOGY
Prepared by: Mary Cielo J. Araneta
Forming and shaping processes in manufacturing involve altering the shape of a raw
material, most commonly metal, through plastic deformation without adding or
removing material. These processes apply forces like bending, compression, or tensile
forces to achieve a desired shape. Common Forming Processes
like forging, rolling, extrusion, drawing and sheet metal forming to deform solid
metal into new forms. While the Shaping Processes generally involve changing
material form by casting or molding , powder metallurgy starting from a fluid or
powder state.
Common Forming Processes
The Rolling process is a metal forming technique where
material is passed between rotating cylindrical rollers to
reduce its thickness and stretch its length, while
maintaining its volume and uniform cross-section.
Types of Rolling Process
• Products of the Rolling Process
• Rolling is used to produce a wide array of metal products, including:
• Metal sheets, plates, and strips
• Rods and bars
• Structural sections like I-beams and railroad tracks
• Pipes and wires
• Components for automotive and electrical industries
The Forging is a forming process in manufacturing where a metal workpiece is shaped by
applying localized compressive forces, often using hammers, presses, or dies. It is
classified by the temperature at which it is performed (hot, warm, or cold forging) and
involves deforming the metal plastically to create parts with increased strength and
improved grain structure.
Types of Forging Processes
Hot Forging performed above
the metal's recrystallization
temperature, allowing for
easier deformation with less
work hardening.
Cold Forging done at or near
room temperature, which
provides a high degree of
precision and a good surface
finish but can require more
force.
Open Die Forging metal is
placed between an open die
and a hammer, with the die
not fully constraining the metal
flow, used for large, simple
shapes.
Impression-Die (Closed-Die)
Forging the metal is fully
enclosed in a die with a pre-
cut shape, forcing the metal to
flow into the die's intricate
contours.
Seamless Rolled Ring Forging
used to produce seamless rings
by rolling the metal between
specially designed dies.
Products of forging process
Extrusion is a manufacturing process that
involves forcing a material through a die of a
specific cross-sectional shape to create long,
continuous objects with a fixed profile.
Types of Extrusion Processes
Hot extrusion is a type of extrusion process
where the billet (workpiece) is heated above
its recrystallization temperature before
being forced through a die.
Cold extrusion is an extrusion process
carried out at room temperature or
slightly above room temperature, meaning
below the material’s recrystallization
temperature.
Direct extrusion, also known as forward
extrusion, is the most common extrusion
process. It works by placing the billet in a
heavy walled container. The billet is pushed
through the die by a ram or screw.
Indirect extrusion is defined
as a metal forming process
characterized by no friction
between the billet and the
container wall, allowing for lower
extrusion loads, higher speeds,
and a more uniform metal flow,
which reduces defects and
increases the service life of
tooling.
Hydrostatic extrusion (HE) is a material
shaping process where a solid billet is
placed in a fluid-filled chamber and pushed
through a die by the uniform pressure of
the liquid.
Products of Extrusion
Metal rods
Pipes and Tubes
Railings
Drawing is a metal forming process in which a metal workpiece
is pulled (drawn) through a die to reduce its cross-sectional
area and increase its length.
Types of Drawing processes
The wire drawing process is a cold plastic
deformation method in manufacturing used to
reduce the diameter of a metal rod or wire by
pulling it through a series of conical dies,
which have progressively smaller, precisely
shaped holes.
The tube drawing process uses
a die and sometimes an internal
mandrel to reduce the diameter
and wall thickness of a metal
tube, improving its precision,
surface finish, and mechanical
strength through cold working.
Bar Drawing similar to wire drawing, but
for larger diameter bars and rods.
Product of Drawing
Electrical Wires
Medical Tubes
Shafts
Sheet metal forming is a manufacturing process used to
shape flat sheets of metal into desired 3D forms without
removing material.
Types of Sheet Metal Forming
Bending is a sheet metal forming
process in manufacturing
technology that deforms a flat sheet metal
along a straight axis to create a V-shape, U-
shape, or channel shape without cutting or
changing its volume.
Deep drawing is a sheet metal
forming process that uses a
punch to radially draw a flat
metal blank into a forming die,
creating a hollow, three-
dimensional part with significant
depth.
Hydroforming is an advanced manufacturing
process that uses high-pressure liquid,
typically water, to shape sheet metal into
complex, high-strength components in a single
step.
Laser cutting is a high-
precision subtractive
manufacturing process for sheet
metal that uses a computer-
controlled, high-energy laser
beam to heat, melt, or vaporize
material, removing it to create
precise shapes.
Primary Shaping Processes
Casting pouring molten metal into a mold to get a specific shape.
Some types of Casting
Sand casting hgh Continous Casting
Primary Shaping Processes
Powder Metallurgy is a manufacturing process where metal powders are compacted into a
desired shape and then sintered (heated below melting point) to form a solid, strong part.
Primary Shaping Processes
Molding is a manufacturing process where a fluid or pliable raw material (like molten
plastic, metal, or rubber) is shaped by being poured or forced into a mold cavity.
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