Forming Processes

A manufacturing activity that changes the shape of a material, without significantly reducing its mass or weight.

Three Major Elements of Forming

Shaping device (dies and rolls) Material temperature Method of applying force

Hot Forming Metals

Hot Forming Definition

Hot forming of metals is done ___ABOVE__ the materials recrystallization temperature. If a materials temperature is maintained above its recrystallization point, then _NEW & SMALLER_ crystals will continue to grow.
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Grain growth during hot forming not cold forming

COLD
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Grain Images / Models

Van Vlack, Elements of Materials Science and Engineering, 3rd Ed.

Heat allows grains to grow anneal metal soften and less brittle more ductile.
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Hot Forming vs. Cold Forming

Less force needed Major shape changes possible

No heating Closer tolerances Better surface finish

Hot Forming Advantages

_Hardness_ and _Ductility_ of the metal is unchanged. _Less_ force is required to hot form when compared to cold forming.

Hot Forming Metals

Six Hot Forming Processes

_Forging_ _Extrusion_ _Roll Forming_ _Piercing_ _Drawing_ _Spinning_

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Hot Forming Processes

Forging produces a part near its final _size_ and _shape_. Forging allows you to control _grain_ direction. Grain: page 117, Fig. 10-3

Hot Forming Metals

Todd, Allen, Alting:

Forging

Manufacturing Processes Reference Guide

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Todd, Allen, Alting:

Forging

Manufacturing Processes Reference Guide

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Extrusion

Extrusion forces metal through a _hollow_ , shaped die which is mounted onto a pressure chamber. Dies must be kept _lubricated_ to keep the metal from coming in contact with the steel dies.

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Extrusion

Direct extrusion

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Extrusion

Indirect extrusion

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Roll Forming
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Roll forming involves forming flat stock into _round_ tubular stock and then _welding_ the seam.

Yoder Mfg.

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Welding Rolled Tube

Yoder Mfg.

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Piercing

Piercing produces _seamless_ tubing. In the tube piercing process a heated rod, revolving between two rollers, is hollowed out by the _mandrel_.

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Seamless tube forming

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Hot drawing

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Primary Steel Processing

encarta.msn.com

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Haiko Hebig

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Progressive Roll Forming

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AltaSteel