Objectives

On completion of this lesson, you would be able to

• Define mechanical working

• Identify the Purpose of mechanical working of metals.
• Classify forming (metal working) processes.
• Define of hot working and cold working.
• Differentiate the advantages and limitations of hot working
and cold working.

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 Recap
• Fundamentals of plastic deformation
• Various lattice defects and their influence on plastic
deformation and mechanical properties metals and
alloys

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 What are these?
Try to identify and name them !!!

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 What are these?
Try to identify and name them !!!

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• Have you identified and named the components/
products in the slides shown ?

• Can you guess how they are made ?

• All these are wrought products and made by various

mechanical (metal) working processes.

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 Wrought product:
• Finished and semi finished products manufactured by
mechanical working from large ingot.

Cast product:
• Products made by casting the metal in to a sand mould or
metal mould.

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 Cast products Vs Wrought products

• Invariably contains • Cast defects are closed

defects such as blow and eliminated during
holes, porosity etc. mechanical working.

• Coarse microstructure • Fine grains and refined

and columnar grains microstructures makes it
makes it brittle and weak. strong and tough.

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 Mechanical working of metals
• Shaping of metals by the application of loads at a proper
temperature.

Purpose of mechanical working:

• To produce various shapes for general engineering use.

• Thin sheets or wires (simple shapes).

• I beams, steel rails, embossed coins, crank shafts and

motor car bodies (complex shapes).

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 Mechanical working of metals

• Improvement of mechanical properties of metals and alloys.

• work (strain) hardening.

• development of tougher microstructure.

• refinement of grain size.

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 Classification of forming processes
(basis: types of forces applied to work piece)

Direct compression type processes

• Force is applied to the surface of the work piece.

• Metal flows perpendicular to the direction of

compression.

ex: forging and rolling.

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Direct compression type processes

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 Classification of forming processes (Contd..)
(basis: types of forces applied to work piece)
Indirect compression type processes
• Primary applied forces are frequently tensile.

• Indirect compression forces are developed by the

reaction of the work piece at the die.

Eg: Extrusion, wire drawing and deep drawing.

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Indirect compression type processes

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 Classification of forming processes (Contd..)
(basis: types of forces applied to work piece)

Tension type processes

• Application of tensile forces.

Eg: Stretch forming.

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Tension type processes

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 Classification of forming processes (Contd..)
(basis: types of forces applied to work piece)

Bending type processes

• Application of bending moment to the sheet.

Eg: Bending.

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Bending type processes

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 Classification of forming processes (Contd..)
(basis: types of forces applied to work piece)

Shearing type processes

• Application of shearing forces of sufficient magnitude to
rupture the metals in the plane of shear.

Eg: Shearing of plates and sheets.

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Shearing type processes

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 Mechanical working processes
Primary mechanical working processes
• Designed to reduce an ingot or billet to a standard mill
product of simple shapes such as bars,plates,sheets.
• Eg: Rolling, forging and extrusion.

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 Mechanical working processes
Secondary mechanical working processes
• Forming methods to produce a part to a final finished
shape.

Eg: sheet metal forming, wire drawing and tube drawing.

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Classification of forming processes
(basis: Temperature in metal working)

Mechanical working

Hot working Cold working

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 Hot working:
• Plastic deformation of metals and alloys above the
temperature (Recrystallisation temperature) at which a
strain free microstructure is produced continuously.

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 Cold working:
• Plastic deformation of metals and alloys below the

recrystallisation temperature.

• Metals and alloys are strain (work) hardened.

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Cold working Vs Hot working

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Cold working Hot working
Working of metals and alloys Working of metals and alloys
below their recrystallisation above their recrystallisation
temperature. temperature.

Strain (work) hardening Strain (work) hardening is

takes place. removed by recrystallisation.

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Cold working Hot working
Increase in hardness and No change in mechanical
tensile strength while properties
ductility decreases.
Microstructure shows Microstructure shows
distorted grains along the equiaxed and usually refined
direction of working. grains.

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Cold working Hot working
Stress and energy required Stress and energy required
for plastic deformation is for plastic deformation is
more. less.

No oxidation of metal occurs Heavy oxidation of metal

and hence pickling is not occurs and hence pickling is
required. required.

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Cold working Hot working
Surface decarburization in Surface decarburization in
steels does not occur. steels is likely to occur.

Metals and alloys does not Reactive metals get severely

get embrittled by oxygen embrittled by oxygen.

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Cold working Hot working
Surface finish is good. Surface finish is not so good.

Easy to control the Difficult to control the

dimensions within the dimensions within the
tolerance limits. tolerance limits

Handling of materials is Handling of materials is

easy. difficult.

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Cold working Hot working
Retains chemical Reduces chemical
heterogeneity if present. heterogeneity of ingots.

Continuous working beyond Continuous working is

a certain limit is not possible possible without cracking.
without cracking.

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