Some Basics Concepts of Metal

Forming

•Rolling
•Forging
•Extrusion
•Drawing

Dr. Ankur Chaurasia

Faculty,
School of Technology,
PDPU, Gandhinagar
 Introduction
 Large group of manufacturing processes in which
plastic deformation is used to change the shape of
metal workpiece.
 The tool, usually called a die, applies stresses that
exceed yield strength of metal.
 The metal takes a shape determined by the
geometry of the die.
 Stresses in Metal Forming
 Stresses to plastically deform the metal are usually
compressive
 Examples: rolling, forging, extrusion

 However, some forming processes

 Stretch the metal and wire drawing (tensile
stresses)
 Others bend the metal (tensile and compressive)
 Still others apply shear stresses (Punching and
Blanking operation)
 Properties of metal

 Desirable material properties:

 Low yield strength and high ductility
 These properties are affected by
temperature:
 Ductility increases and yield strength decreases when
work temperature is raised
 Other factors:
 Strain rate (It is the change in strain (deformation) of
a material with respect to time) and friction.
 Classification of metal working process
 The classification of metal working processes are
based on two criteria.

1) Type of force (Given in next slide)

2) Temperature of working Hot working

Cold working
Based on type of Force applied
 Plastic deformation
 Deformation beyond elastic limits.
 Due to slip, grain fragmentation, movement of atoms
and lattice deformation.

 Stress-Strain diagram (we have to understand)

Flow stress/True Stress

 Recrystallisation
 The minimum temperature at which the completed
recrystallisation of a cold worked metal occurs within
a specified period of time.
 Recrystallisation is a process in which at a certain
temperature new equi-axed and strain free grains
are formed and replacing the older grains.
 Rx, decreases strength and increases ductility.
 If working above Rx, hot working process
whereas working below are cold working.
 It involves replacement of cold worked structure by
a new set of strain free, approximately equi-axed
grains to replace all the deformed crystals.
 Continued….
 Rx depends on the amount of cold worked a
material has already received.
 Rx= 0.4 x Melting point (0.3-0.5 of melting point)
 Rx of iron is 450 degree and for steel is 1000
degree.
 Finer is the grain lower will be the Rx.
Classification based on Temperature

 Based on temperatures of working the metal forming

process can be divided into three groups.
 In practical application grain growth is not desirable.
 The driving force for this process is reduction in grain
boundary.
 Incorporation of secondary phase particle grain retards the
grain growth.
 Grain growth is strongly dependant on temperature.
 Hot Working
 Hot working involves deformation of preheated material at
temperatures above the re-crystallization temperature.

 Hot working results in grain refining.

Refined
Grains
 Higher temperature of metal give rise to scaling of
the surface and as a result, the surface finish
obtained is poor.

 Because of thermal expansion of metals, the

dimensional accuracy in hot working is hard to
achieve since it is difficult to control the temperature
of workpieces.
 Hot Working
 Advantages  Dis-Advantages
 Higher ductility – more  Poor surface finish, due to the
deformation without cracking. rapid oxidation and scale
 Lower flow stress – less formation of the metal.
mechanical energy required for  Dimension tolerance is poor
deformation. due to thermal expansion at
 Porosity may be largely high temperatures.
eliminated.  Handling is more (from
 Smaller grain size. Finer grain furnace to machine).
obtained  It requires expensive tools.
 The mechanical properties such
as elongation, percentage
reduction in area , resistance to
shock and vibration are improved
due to refinement of grain.
 Cold Working

 Normally performed at room temperature where

Recrystallisation does not occur.

 Work hardening/ Strain Hardening occurs (strength and hardness

increase but ductility decreases).

 The extent of deformation is rather limited if cracks are to be

avoid, therefore intermediate anneals that enable recrystallisation
are frequently used afterwards.

 The materials suitable for cold working should have a relatively

low yield stress and a relatively high work hardening rate
(determined primarily by its tensile properties).
 Cold Working
 Advantages
 Provide work hardening, materials are stronger.
 Provide fine grain size and good surface finish.
 Dimension tolerance is better than in hot working.
 Easier handling (low operating temperatures).
 Better surface finish.
 Grain flow during deformation can cause desirable directional
properties in product.
 Dis-Advantages
 Use high amount of forces and power are required. (Rigid set
up is required)
 Surface must be free of scale and dirt.
 Equipment (rolls, dies, presses) is big and expensive.
 Reduced ductility, therefore, require subsequent annealing
treatments.
As grain deformation proceeds, greater resistance to this action results in
increased hardness and strength. The metal is said to be strain hardened.

Strain Hardening: Work hardening, also known as strain hardening is the

strengthening of a metal by plastic deformation. This strengthening occurs
because of dislocation movements and dislocation generation within the crystal
Flow
structure of the material. Many non-brittle metals with Stress high
a reasonably
melting point shows this behavior.
Thanks