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MAURBHANJ SCHOOL OF ENGINEERING

BARIPADA : 757107 , ODISHA

CHAPTER – 01

TOPIC- METAL FORMING PROCESS

BRANCH- MECH.

SEMISTER- 3rd

SUBJECT- PRODUCTION TECHNOLOGY

FACULTY- ER S BARIK

Estd:.1994

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METAL FORMING PROCESS

  • METAL FORMING: Large set of manufacturing process in which the material is deformed plastically to take the shape and size of the die geometry.The tools used for such deformation are called die, punch, etc.depending on the type of process.
  • PLASTIC DEFORMATION: Stresses beyond yield strength of the workpiece material is required.
  • CATEGORIES: Bulk metal forming , Sheet metal forming

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GENERAL CLASSIFICATION OF METAL FORMING PROCESSES

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CLASSIFICATION OF BULK FORMING PROCESSES

BULK FORMING: It is a severe deformation process resulting in massive shape change. The surface area to volume of the work is relatively small. Mostly done in hot working conditions.

  • Rolling Process
  • Forging Process
  • Extrusion Process
  • Wire or rod drawing Process

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ROLLING PROCESS

  • In this process, the workpiece in the form of slab or plate is compressed between two rotating rolls in the thickness direction, so that the thickness is reduced. The rotating rolls draw the slab into the gap and compresses it. The final product is in the form of sheet.

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FORGING PROCESS

  • The workpiece is compressed between two dies containing shaped contours. The die shapes are imparted into the final part.

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EXTRUSION PROCESS

  • In this process, The workpiece is compressed or pushed into the die opening to take the shape of the die hole as its cross section.

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WIRE OR ROD DRAWING PROCESS

  • Similar to extrusion process, except that the workpiece is pulled through the die opening to take the cross – section.

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CLASSIFICATION OF BASIC SHEET FORMING PROCESSES

SHEET FORMING: Sheet metal forming involves forming and cutting operations performed on metal sheets, strips, and colis. The surface area to volume of ratio of the starting metal is relatively high. Tools include punch,die that are used to deform the metal sheets.

  • Bending
  • Deep (or cup) drawing
  • Shearing

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METAL SHEET BENDING

  • In this process, the sheet material is strained by punch to give a bend shape (Angle shape) usually in straight axis.

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DEEP (OR CUP) DRAWING

  • In this operation, forming of a flat metal sheet into a hollow or concave shape like a cup, is performed by stretching the metal in some regions. A blank holder is used to clamp the blank on the die, while the punch pushes into the sheet metal. The sheet is drawn into the die hole taking the shape of the cavity.

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SHEARING PROCESS

  • This is nothing but cutting the metal sheets by shearing action.

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Created by – ER KHAGESWAR PATRA