Deformation Process (Metal Forming)
Types of Deformation Process
Bulk Deformation
Hot metal Gas Froming(HMGF)
A method of die forming which heats a metal tube
and exerts internal pressurizing to from a tube in
outward and higher elongations of a tube
Highly used in automative and aerospace industries
Powder Metulurgy
Consist of exertion of compressive force over a powder metal blending it to form a derired strutuerd in a die
Four steps of PM
Powder Manufacture
Powder blending
Compacting
Sintering
Friction Drilling
Thermal drilling is a process that uses high friction and high thermal energy to produce bushings in metal tubing and flat stock.
Cold Sizing
Sizing Pressure of a die is determined
by the size, type of metal, and
dimensional properties
Can be performed on both ferrous
and non ferrous metals, non metals,
Polymers and plastics
Consist of squeezing operation
of a metal between open die
Extrusion
Process of thrusting or drawing a material
through a die with a predetermind cross
-sectional area
Can be performed on metals, ceramics,
plastics and polymers
Requirments for operation
Movement of extrusions
Direct extrusion
Ram or screw is used to push the billet through the die
causing extrusion of the material
Indirect extrusion
Billet and container moves together through the die
causinng extrusing of material
Hydrostatic extrusion
Consist of a pressurized liquid around
the billet allowing it to move through the die
Position of the presss
Horizontal Position
Vertical Position
Processes to commute
Mechanical process
Hydraulic process
Imparting load
Conventional
Hydrostatic
Forging
Consist of conventional compressive force to
form a desirble structure.
Types of Process
Compresion
Drawing
upset
Sheet Metalworking
Bending
Types of Bending
Air bending
Punching into the workpiece positioned
on a desired shaped die block
Bottoming
A sheet metal is punched against
the V-shape ram
Coining
The top V- shape ram move along with the workpiece punching it against the die block to form a V- shape.
Roll Bending
Consist of sets of rollers to bend the sheet metal
Rotary Bending
Similar to Roll Bending
A process of producing V-shape, U- shape
and channels by punching a tool on a
workpiece [p
Sheering and stamping
A Punch is used to impart a sheer force on the workpiece
against the die, causing to form into a desired shape.
Roll froming and Bending
Consist of sets of rollers to bend the sheet metal
Deep Drawing
A sheetmetal is punched by a ram and drawn
to its depths radially
Spinning
Used to form a axially symmetry in a part by
spinnig a disc or tube of metal at high speed
Final Product to be extracted
Design of Final Product
Geomatrical Properties
Accurate dimensions
Length, height, weight,volume and area
Internal and external thickness
Sharp intersecting points
Allowances and fittings
Smooth Surfaces
Drafts
Types of Materials
Metal : Ferrous and Non Ferrous
Non- Metals
Ceramics
Polymers
Plastics
Chemical and Physical Properties
Thermal Stability
Sustainibility
Malleable
Strength
Ductile
Types of working
used in each process
Cold working
Advantage
Better Accuracy and closer tolerance
Better surface finish
Strain hardening increases strength and hardness
Grain flow during deformation can cause desirable directional properties in product
No heating of work required
Disadvantage
Higher forces and power required in the deformation operation
Surfaces of starting workpiece must be free of scale and dirt
Ductility and strain hardening limit the amount of forming
Hot working
Advantage
Lower forces and power than in cold working
More intricate work geometries possible
Need for annealing may be reduced or eliminated
Warm working
Advantage
Workpart shape can be significantly altered
Lower forces and power required
Metals that usually fracture in cold working can be hot formed
Strength properties of product are generally isotropic
No strengthening of part occurs from work hardening
Diadvantage
Lower dimensional accuracy
Higher total energy required (due to the thermal energy to heat the workpiece)
Work surface oxidation (scale), poorer surface finish
Shorter tool life
Friction
In most metal forming processes, friction is undesirable
Metal flow is retarded
Forces and power are increased
Tooling wears faster
Friction and tool wear are more severe in hot working
Lubrication
Benefits
It reduce harmful effects of friction
Reduced sticking, forces, power, tool wear
Better surface finish
Removes heat from the tooling
Considerations in Choosing a Lubricant
Type of forming process (rolling, forging, sheet metal drawing, etc.)
Hot working or cold working
Work material
Chemical reactivity with tool and work metals
Chemical reactivity with tool and work metals
Cost
Material
Production
Tooling
Machining
Mechanical or Hydraulic drived Cylinders
Allows us to drive Ram
Allows us to move Dies and Workpieces
Allows us to drive other components of the system
Allows us to move Work billets and die holding containers
Complex structural designs
through Computer Numerical
Controls (CNC)
Drilling
Cutting
Routing
Rabettig
Threading
Millling Machines
Inspection
Non- Destructive Test
Maintainace Testing
Product Verification
Faliure analysis
Quality control
Stress Analysis