dr. amr shehata fayed fundamentals of metal forming processes amr shehata fayed, ph.d. assistant...

Dr. Amr Shehata Fayed

Fundamentals of Metal Forming Processes

Amr Shehata Fayed, Ph.D.Assistant Professor of Mechanical Engineering

Materials Engineering DepartmentFaculty of Engineering

Zagazig University

2Dr. Amr Shehata Fayed

Shaping: usually involves molding and casting.

Ex. The white ceramic insulator for a spark plug of a car body for a car (clay molding, drying and firing)

Forming and Shaping

Forming: means changing the shape of an existing solid body.

Ex. The metal body for a car (sheet metal forming)


Metal Forming Processes

• Metal Forming includes a large group of

manufacturing processes in which plastic

deformation is used to change the shape of

metal work-pieces.

• Deformation results from the use of a tool,

usually a die in metal forming, which applies

stresses that exceed the yield strength of the

metal.


Hammer forging two connecting rods; (a) bar stock; after (b) fullering, (c) “rolling”, (d) blocking, (e) finishing, (f) trimming; (g) the flash; (h) the forging dies.

(a) (b) (c) (d) (e) (f) (g) (h)


Bulk Deformation:

Compressive deformation force.

Significant deformations.

Massive shape changes.

Starting work shapes include

billets and rectangular bars.

Surface area / volume is small.


Sheet Metal-working:

Also called “Press-working”.

Cold working processes.

Use set of punch and die.

Performed on metal sheets,

strips and coils.

Surface area / volume is large.


Surface Area / Volume is large

Bending operations

Shearing processes

Deep or Cup drawing

Sheet Metalworking

Surface Area / Volume is small

Rolling

Forging

Extrusion

Wire and Bar drawing

Bulk Deformation



Rolling: A compressive deformation process in

which the thickness of slab or plate is reduced by

two opposing tools “rolls”. They rotate to draw the

work piece into the gap between them and

squeeze it.

Bulk Deformation Processes


Forging: The work-piece is compressed between two

opposing dies so that the die shapes are imparted to

work. It is traditionally hot working process however

many types of forging are performed cold.



Extrusion: A compressive deformation process in

which the work metal is forced to flow through a die

opening to produce a desired cross-sectional shape.



Drawing: The work metal is being pulled through a

die opening to reduce the diameter of a wire or a bar.

See Fig. Wire Drawing.



Examples of PrecisionCold Forged Products


Precision Hot Forging of Complex Shapes


Bending: It involves straining of metal sheet or plate

to take an angle along a (usually) straight axis.

Sheet Metalworking Processes


Drawing: (Cup or deep drawing) Forming of a flat

metal sheet into a hollow or concave shape, such as

cup, by stretching the metal. A blank holder is used

to hold down the blank while the punch pushes into

the sheet metal.



Shearing: It involves cutting rather than forming of

a metal. A shearing operation cuts the work using a

punch and die.



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


Applications and Products of Metal forming in Macro Scale

• Automotive

• Aerospace

• Appliance

• Cookware


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


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.


Homework

• Is metal forming the most cost effective manufacturing process?

• Why metal forming is the best process for mass production?

• According to your imagination, what is the best process to make beverage can?

dr. amr shehata fayed fundamentals of metal forming processes amr shehata fayed, ph.d. assistant...

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