FORMATION AND DEFORMATION

Fullname Elisabet Bertania Cahyaningtias

Student ID 2514 100 027
Email elisabetbertania@gmail.com
I. ABSTRACT
This paper is conducted for describing the formation and deformation process
begin with the general definition of formation and deformation, the importance of
formation and deformation in manufacturing process, the type of formation and
deformation, the weakness and strength of formation and deformation, and the
last is the concrete examples of formation and deformation.
Formation is particular manufacturing process which make use of suitable
stresses (like compression, tension, shear or combined stresses) to cause plastic
deformation of the materials to produce required shapes. In the process of
formation, there is a process of deformation because plastic deformation is used
to change the shape of metal work pieces. Deformation is the process to
transform solid materials from one shape into another. Formation and
deformation is very important in manufacturing process because it enjoys
industrial importance among various production operations due to its advantages
such as cost effectiveness, enhanced mechanical properties, flexible operations,
higher productivity, and considerable material saving. The types of formation are
bulk deformation process and sheet metal working process. The weakness of the
formation process is the higher mount of force and energy is required for metal
forming process compared to other manufacturing methods, and many more
weaknesses. The strength of the formation process is the surface finish obtained
on the component is very good and excellent, and many more advantages. The
product examples of formation and deformation process are car body, gear, tin,
machinery pins, etc.
Keywords: Manufacturing, Process. Formation, Deformation
II. INTRODUCTION
Practically, all metals which are not used in cast form are reduced to some
standard shapes for subsequent processing like metal forming or we can call
formation. Metal forming is a manufacturing process in which forces are applied
on raw material such that stresses induced in the material are greater than yield
stress and less than ultimate stress. (Chennu, 2014). Moreover, formation or
metal formation is particular manufacturing process which make use of suitable
stresses (like compression, tension, shear or combined stresses) to cause plastic
deformation of the materials to produce required shapes. The workpiece is
reshaped without adding or removing material, and its mass remains unchanged.
In the process of formation, there is a process of deformation because plastic
deformation is used to change the shape of metal work pieces. Deformation is
the process to transform solid materials from one shape into another. The initial
shape is usually simple (a billet or sheet blank) and is plastically deformed
between tools, or dies, to obtain the desired final geometry and tolerances with
required properties (Altan, 1983) In deformation process there are 2 types, which
are elastic deformation and plastic deformation. Elastic deformation is a change
in shape of a material at low stress that is recoverable after the stress is
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removed. In other words, a temporary shape change that is self-reversing after

the force is removed, so that the object returns to its original shape, is called
elastic deformation. Moreover, plastic deformation is a change in shape when the
stress is sufficient to permanently deform the metal, so the change in shape is
permanent although the stress is vanished. But, casually the formation or metal
forming use the plastic deformation to change the metal shape.
Metal forming or formation is a very important manufacturing process. It
enjoys industrial importance among various production operations due to its
advantages such as cost effectiveness, enhanced mechanical properties, flexible
operations, higher productivity, and considerable material saving. In the
manufacturing process, formation is a widely used process which finds
applications in automotive, aerospace, defense, and other industries.
Deformation is also importance in manufacturing process, because every
formation is always need deformation to change the shape of metal.
(Chandramouli, n.d.) So, formation and deformation is very important in
manufacturing process.
III. ANALYSIS AND DISCUSSION
The formation and deformation have various types. Typically, metal forming
processes can be classified into two basic categories. One is bulk deformation
processes and the other is sheet metal working processes.
Bulk deformation processes are generally characterized by significant
deformations and massive shape changes, and the surface area to volume of the
work is relatively small. The term bulk describes the work parts that have this low
area to volume ratio. Starting work shapes for these processes include cylindrical
billets and rectangular bars. (Groover, 2010) In bulk deformation processing
methods, the nature of force applied may be compressive, compressive and
tensile, shear or a combination of these forces. Bulk deformation processes have
the following characteristics:
1. The work piece undergoes large plastic deformation, resulting in an

appreciable change in shape or cross section.

2. The portion of the work piece undergoing permanent plastic deformation is
generally much larger than the portion undergoing elastic deformation.
Therefore, elastic recovery or spring back after deformation is negligible.
(Altan, 1995).
The example of bulk deformation process is rolling, forging, extrusion, and
drawing.
1. Rolling: this is a compressive deformation process in which the thickness of
a slab or plate is reduced by two opposing cylindrical tools called rolls. The
rolls rotate so as to draw the work into the gap between them and squeeze
it.
2. Forging: In forging, a work piece is compressed between two opposing
dies, so that the die shapes are imparted to the work. Forging is
traditionally a hot working process, but many types of forging are
performed cold working.

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3. Extrusion: This is a compression process in which the work metal is forced

to flow through a die opening, there by taking the shape of the opening as
its own cross section.
4. Drawing: In this forming process, the diameter of a round wire or bar is
reduced by pulling it through a die opening. (Groover, 2010)
Sheet metal working process are forming and cutting operations performed on
metal sheets, strips, and coils. The surface area-to-volume ratio of the starting
metal is high, thus, this ratio is a useful means to distinguish bulk deformation
from sheet metal processes. Press working is the term often applied to sheet
metal operations because the machines used to perform these operations are
presses (presses of various types are also used in other manufacturing
processes).A part produced in a sheet metal operation often called a stamping.
Sheet metal operations are always performed as cold working processes and are
usually accomplished using a set of tools called a punch and die. The punch is
the positive portion and the die is the negative portion of the tool set. (Groover,
2010) The characteristics of sheet metal working processes are as follows:
1. The work piece is a sheet or a part fabricated from a sheet.
2. The deformation usually causes significant changes in shape but not in
cross-section of the sheet.
3. In some cases, the magnitudes of permanent plastic and recoverable
elastic deformations are comparable; therefore, elastic recovery or spring
back may be significant. (Altan, 1995)
The basic sheet metal operations are defined as follows:
1. Bending: Bending involves straining of a metal sheet or plate to take an
angle along a (usually) straight axis. Bending of sheets includes rotary
bending, swivel bending, and roll bending using rotary die. Die bending
using flat die or shaped die is used for bending of sheets, or die coining of
sheets.
2. Cup or deep drawing: In sheet metalworking, drawing refers to the forming
of a flat metal sheet into a hollow or concave shape, such as a cup, by
stretching the metal. A blank holder is used to hold down the blank while
the punch pushes into the sheet metal. To distinguish this operation from
bar and wire drawing, the terms cup drawing or deep drawing are often
used.
3. Shearing: This process seems somewhat out of place in a list of
deformation processes, because it involves cutting rather than forming. A
shearing operation cuts the work using a punch and die. Although it is not
a forming process, it is included here because it is a necessary and very
common operation in sheet metalworking. (Groover, 2010)
Formation and deformation process are surely have the strengths and
weaknesses. The strengths or advantages of metal forming process are:
1.
The amount of wastage of metal during metal forming process is
negligible.
2.
Grain orientation is possible.
3.
Because of grain orientation the material is converted from isotropic to
anisotropic material.
4.
In most of engineering applications it requires anisotropic material.
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5.
6.

Sometimes the strength and hardness of work material is increasing.

Some other metal forming process, the surface finish obtained on the
component is very good and excellent.
The weaknesses or disadvantages of the metal forming process are:
1.
Higher mount of force and energy is required for metal forming process
compared to other manufacturing methods.
2.
Except the forging operation, all other metal forming process is used for
producing uniform cross sectioned components only.
3.
The components with cross holes cannot be produced easily using metal
forming process. (Chennu, 2014)
The example of formation and deformation process is the process to product
the automotive tools like SmartClima, the producer of many manufacturing tools
in China which produce ring gears, terminal ends, long pins, machinery pins, car
& auto pins, textile industry pins, custom socket, heading rivets, and so on which
made by metal cold forging process. (SmartClima, 2008) The example of sheet
metal working process is the making of car body, car chassis, other car parts, and
the making of tin and tube are also use sheet metal working process.
IV. CONCLUSION
The formation or metal forming is a particular manufacturing process which
make use of suitable stresses (like compression, tension, shear or combined
stresses) to cause plastic deformation of the materials to produce required
shapes. In the process of formation, there is a process of deformation because
plastic deformation is used to change the shape of metal work pieces in the
metal forming process. Deformation is the process to transform solid materials
from one shape into another. There are 2 types of deformation which are elastic
deformation and plastic deformation. The types of metal forming are bulk
deformation and sheet metal working. Metal forming or formation is a very
important manufacturing process. It enjoys industrial importance among various
production operations due to its advantages such as cost effectiveness,
enhanced mechanical properties, flexible operations, higher productivity, and
considerable material saving.
V. REFERENCES
Altan, T. 1983. Metal FormingFundamentals and Applications. Metals Park,
Ohio: ASM International
Altan, T., 1995. Unit Manufacturing Processes. 1st ed. Washington, D.C.:
NATIONAL ACADEMY PRESS.
Chandramouli, R., n.d. Fundamental concepts of metal forming technology. 5
December, p. 3.
Chennu,
V.
R.,
2014.
Mechanical
Engineering.
[Online]
Available at: http://me-mechanicalengineering.com/metal-forming-process/
[Accessed 5 December 2015].
Groover, M. P., 2010. Fundamentals of Modern Manufacturing. 4th ed. United
States of America: John Wiley & Sons, Inc..
SmartClima,
2008.
SmartClima.
[Online]
Available
at:
http://www.smartclima.com/metal-cold-forging.htm
[Accessed 5 December 2015].

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