MANUFACTURING TECHNOLOGY I SUB CODE: MEC230 Unit 2 Welding (Metal Joining) Processes & Metal Forming Processes

Unit 2 : Metal Forming Processes

Metal Forming Processes :

The importance of metals in modern technology is due to the ease with which they may be formed into useful shapes like tubes, rods and sheets The useful shape may be generated by two basic ways Plastic deformation processes:- The volume and mass of metal are conserved and metal is displaced from one location to another Metal removal or Machining processes:- In which material is removed in order to give the required shape

Metal Forming Processes :

Forming can be defined as the process in which the desired size and shape of the objects are obtained through plastic deformation of material The stresses induced during the process are greater than yield strength but should be less than the fracture strength Different types of loading may be used depending on the process Tensile Compressive Shear Bending

Classification of Metal Forming Process:

Metal forming process may be classified on the basis of type of forces applied to the work piece as it is formed into direct shape Direct compression type process (e.g.-Forging, Rolling) Indirect compression process (e.g.-Extrusion, Wire Drawing) Tension type process (e.g.-Stretch forming) Bending process Shearing process

Direct Compression type Process (Forging)

Direct Compression type Process (Rolling)

Indirect Compression Process (Extrusion)

Indirect Compression Process (Drawing)

Indirect Compression Process (Deep Drawing)

Tension type process (Stretch forming)

Bending process

Shearing Process

Classification of Metal Forming Process

Classification of Metal Forming Process

Classification of Metal Forming Process:

Metal forming may also be classified on the basis of working temperature. Hot Working Processes Cold working Processes Warm Working Processes

Hot Working:
Hot working processes the metals are heated recrystallization temperature to given desired shape above

Eg rolling, extrusion or forging are used in the first step of converting a cast ingot into a wrought products. The metals are given desired shape by subjecting them to forces which cause them to undergo plastic deformation when heated above recrystallization temperature.

Advantages of Hot Working Processes

Hot working results in decrease in energy required to deform the metal and increased ability to flow without cracking. Casting defects like blowholes and porosity are eliminated by the welding together of these cavities. Coarse columnar grains of the casting are broken down and refined into smaller equiaxed recrystallized grains. Due to refinement of grains mechanical properties such as toughness, ductility elongation and reduction in area are improved. These changes in structure from hot working result in an increase in ductility and toughness over the cast state.

Disadvantages of hot working processes:

Because of high temperature surface reactions b/w the metal and the furnace atmosphere becomes a problem. As hot working is done in air, oxidation results and a considerable amount of metal may be lost. This results in poor surface finish, and because allowance must be made for expansion and contraction, the dimensional tolerances for hot worked products are greater than cold worked products. Structure and properties of hot worked metals are not generally uniform over the cross section as in metals which have been cold worked and annealed. Since the deformation is always greater in surface layers, the metal will have a finer recrystallized grain size in this region.

Cold Working:
Cold working processes the metals are done at room temperature to given desired shape Cold working of a metal results in an increase in strength or hardness and decrease in ductility. When the cold working is excessive the metal will fracture, before reaching the desired shape and size. Need of annealing operations increase the cost of forming by cold working

Advantages of Cold Working: Produces an improved surface finish, scale free and bright surface and closer dimensional tolerances. Residual stresses are set up in the metals which remain unless they are removed by subsequent heat treatment. Cold working results in loss of ductility and increase of strength and hardness of metal.

Limitations of Cold Working: Only small sized components can be easily cold worked as greater forces are required for larger sections. Grain structure is not refined and residual stresses have harmful effects on certain properties of metals. Many of the metals having les ductility cannot be worked at room temperature. It is therefore limited to ductile metals. Tooling costs are higher and is used when large quantities of similar components are required.

Warm Working:
It is the plastic deformation of a metal at temperature below the recrystallization and above room temperature. It attempts to combine the advantages of both hot and cold working into one operation. Warm working has been applied most extensively to the forging of steel, where it offers fewer forging steps, reduced forging load, and energy savings compared with cold forgings. When compared with hot working it offers advantage of

Improved dimensional control,

Higher quality surface and Lower energy costs.

Advantages of (Mechanical) Metal Working Processes: Defects in metals such as blow holes and porosity find to get filled due to plastic deformation Mechanically worked components exhibit superior mechanical properties Provides grain refinement and improved metallurgical structure of metal Cold working with subsequent annealing can produce good surface finish and close dimensional tolerances

Process is ideal for producing small sized components

Limitations of (Mechanical) Metal Working Processes: Difficult to produce large components

Produces internal stresses, which are to be relieved

Formation of scale by oxidation and decarburization of surface may take place

Cold working may reduce ductility and induces brittleness

Heavy equipments, machineries and manpower are required

Wrought Products: A product is said to be wrought if it is manipulated in the solid state from a cast shape The choice of manipulation depends upon the material to be manipulated, the shape required, the accuracy required and the quantity involved

Wrought forms can be, drawn bars, rolled sections, sheet, plate, tube, wire, extruded sections
A cast metal posses local differences of metallurgical structure and chemical composition, and contains blowholes and the cast metals have inferior mechanical properties Wrought metals are subjected to hot working, this improves the properties of metal

Characteristics of Wrought Products: Hot working imparts directional properties to the metals caused by the deformation of grains along the direction of working The minor defects like blow holes at the sub surface and surface level get eliminated by welding effect when formed The wrought metals generally exhibit superior mechanical properties like strength, ductility and toughness They normally have rough surface finish The surface may undergo oxidation and result in scale formation They may undergo decarburization at the outer surface