Application of Metal
Forming in Manufacturing
Engineering
Jenn-Terng Gau, Ph.D.
Assistant Professor of Mechanical
Engineering
Northern Illinois University
Research Interests
Metal Forming Research
Sheet Metal Micro-Forming Bulk Metal
Forming Forming
Deep Stamping Sheet Bulk Forging Extrusion
Drawing
Importance of Metal Forming in
Manufacturing Engineering
• Net Shape or Close to Net Shape
• High Production Rate
• High Profit Margin
• Low Scrap Rate
• Improving Material Properties
• Etc.
Applications and Products of
Metal forming in Macro Scale
• Automotive
• Aerospace
• Appliance
• Cookware
• Etc.
Current Issues of Metal Forming
Industry
• Lack of Experienced Metal Forming
Engineer
• Short Product Life Cycle
• New Metallic Materials
• Developing New Hybrid Process
• High Accuracy and Small Feature
Products
• Etc.
OVERVIEW OF METAL FORMING
• Bulk Deformation Processes:
- Compressive deformation force
- Significant deformations
- Massive shape changes
Surface
- Starting work shapes include billets
Area / and rectangular bars
Volume
is small
• Sheet metal working:
- Also called “Pressworking”
- Cold working processes
- Use set of punch and die
- Performed on metal sheets, strips
and coils
Surface
Area /
Volume
is large
Metal Forming Processes
Rolling Forging Bending Cup Drawing
Shearing
Extrusion Wire Drawing
Bulk Deformation Processes Sheet Metal Working
Examples of Precision
Cold Forged Products
Precision Hot Forging of
Complex Shapes
Precision Hot Forging of
Complex Shapes
Sheet Metal Forming
Stamping and Deep Drawing
Stamping Process Flow in
Automotive Industry
Product & Process Draw Dev. (CAD) CAE Die Design (CAD)
Production Soft & hard Tool Tryout Machining CAM
Binder Wrap Simulation (CAE)
Forming Simulation (CAE)
40 40
R1 R1
Product Change and Draw
Development Modification
Step widen (25mm
from trim line) Radius enlarge Design „banana“ softer
Optimize bulge
Optimize the cape
Optimize blank
and draw bead
R10
80 80
R1 R1
Lift up surface Reduce height of surface
in this area
Rerun Forming Simulation
80 80
R1 R1
CAE and Tryout Comparison
Simulation with Autoform V2.1
CAE and Tryout Comparison
Simulation with Autoform V2.1
Micro Metal Forming
Sheet and bulk metals
Applications and Products of
Micro Forming
• Cellular Telephones
• IC Leadframes
• Electronics
• Healthcare
• Miniature Fasteners
• Hard Disc Drives
• National Security &
Defense
• Automobiles
• Sensors
• Etc.
Finished Micro Press Design
STEPPER MOTOR
14.00”
ISOMETRIC VIEW
LOAD CELL
TOP VIEW
LVDT
6.75”
SIZE OF MACHINE:
14.00” X 12.00” X 6.75”
(SHOWN WITH DEEP RIGHT VIEW
DRAWING TOOL KIT)
NIU Micro Dies
Skills Needed for Metal
Forming Engineering
• Mechanics
• Material Science
• Manufacturing Process
• Design and Control
• Machinery
• Computer Skills
• FEA
Students Need
• To know the current and future needs of
metal forming industry.
• To be taught on a series of classes to
meet challenges of current and future
metal forming industry.
UEET 101 Problem Domain
• According to your imagination, what is the
best process to make beverage can?
Homework
• Is metal forming the most cost effective manufacturing process?
• Why metal forming is the best process for mass production?
