OVERVIEW

What is forming

Forming
Classification
of metal
working
is a process
in which
the
processes
desired shape and size of the
component is obtained through plastic
of theof
metal.
In simple
deformation
Characteristics
wrought
products
words, the component is formed without
removing any material from it.

If material does not get removed then

naturally when force is impacted on
workpiece fatigue will result ?
The stresses induced in the applied
forces during the forming processes are
greater than the yield strength but less
than the fracture strength of the metal.
The component thus formed possess
better mechanical properties than those
obtained by casting or machining.

Classification of Metal Forming

processes
1.Based on nature of force applied
Direct compression type process
Indirect compression type process
Tension type process
Bending type process
Shearing type process

DIRECT COMPRESSION TYPE PROCESS

FORGING

ROLLING

INDIRECT COMPRESSION TYPE PROCESS

DRAWING

EXTRUSION

TENSION TYPE PROCESS

STRETCH FORMING

BENDING TYPE PROCESS

SHEARING TYPE PROCESS

2. BASED ON WORKING TEMPERATURE

HOT WORKING
COLD WORKING
WARM WORKING

Hot Working
If the workpiece temperature of the metal is
above its recrystallization temperature but
below the melting point the process is
classified under hot working process. Eg:
Forging, rolling, extrusion, drawing,
piercing, etc.

Cold Working
If the workpiece temperature of the metal is
below its recrystallization temperature. Eg:
Bending, shearing, cold forging, cold
extrusion, etc.

Warm working, (or warm forming), is a metal

forming process carried out above the
temperature range of cold working, but below
the recrystallization temperature of the metal.
Warm working may be preferred over cold
forming because it will reduce the force
required to perform the operation. Also, the
amount of annealing of the material that may
have been necessary for the cold formed part
may be less for warm working.

Hot Working
1. Working temp of metal
above its recrystallization
temp.
2. Needs additional
equipments for heating the
workpiece.
3. Stress required for
deforming the metal is low.
4. Low tonnage equipments
needed for process.

Cold Working
Working temp of metal
below the recrystallization
temp.
Workpiece not heated.

Greater stress is required

to deform the metal.
High capacity machines
required for these greater
forces.
5. No strain hardening
Severe residual stresses
effects.
induced in the metal.
6. Grain properties of metal No grain refinement.
are refined.
7. Poor surface finish due
Better surface finish.
to scale formation.
8. Large size components
Not suitable for large
can be hot worked.
components.

Characteristics of wrought products

Wrought means to work
1.Products are formed by deforming the
metal in its plastic state.
2.Wrought products are ductile in nature.
3.They are identified quickly by their
surface finish and sharp corners. They are
free from minor defects such as blow holes,
porosity and surface ireegularities.
4.Products have better mechanical
properties and directional flow lines.
5.Exhibits properties in the direction of
metal flow.

Wrought products
1. Produced by metal
working process.

2. Grain flow is
continuous.
3. Produced in large
size and complex
shapes.
4. Usually ductile and
exhibit superior
mechanical properties.
5. Minimum defects
and surface

Cast products
Produced by casting
liquid metal into
moulds of desired
shape.
Grain flow is random.
No restriction to sizes
and shapes.
Can be ductile and
brittle but properties
slightly lower than
wrought products.
Comparatively more.

Advantages of metal working

processes
Limitations of metal working
processes

Advantages of Metal Working Process

1.Product
with
high quality can
8. The process
canconsistent
be easily machined.
be
manufactured.
9. Desired
shape can be easily achieved with
2.Defects
such as
and
favourable changes
in porosity
microstructure.
discontinuous
are
very
much
minimised.
10. Low wastage of
metal
during
working.
3.Inclusions gets distributed evenly
throughout the product.
4.Grains are oriented in particular direction
and directional properties are obtained.
5.In hot working the grains will be uniform
and the properties also uniform.
6.In cold working the properties are
enhanced due to strain hardening effect.
7.Large tonnage can be easily produced.

Limitations of metal working processes

1.The product becomes highly anisotropic in
nature.
2.Final product has to be obtained after
machining of the wrought product except in
the case of structural components.
3.Needs additional component and
machinery for metal working process.
4.Maintenance cost is high.
5.More safety precautions are to be
exercised as hot metal and additional
equipments are used.
6.Working environment is not good.
7.Not suitable for large size components.