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Fundamentals of Metal Forming Processes

Fundamentals of Metal Forming Processes. Amr Shehata Fayed , Ph.D. Assistant Professor of Mechanical Engineering Materials Engineering Department Faculty of Engineering Zagazig University. Forming and Shaping. Shaping : usually involves molding and casting.

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Fundamentals of Metal Forming Processes

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  1. Fundamentals of Metal Forming Processes Amr Shehata Fayed, Ph.D. Assistant Professor of Mechanical Engineering Materials Engineering Department Faculty of Engineering Zagazig University

  2. Forming and Shaping 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: means changing the shape of an existing solid body. Ex. The metal body for a car (sheet metal forming)

  3. 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.

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

  5. Metal Forming Processes • 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. • Bulk Deformation: • Compressive deformation force. • Significant deformations. • Massive shape changes. • Starting work shapes include billets and rectangular bars. • Surface area / volume is small.

  6. Metal Forming Processes Sheet Metalworking Bulk Deformation Bending operations Rolling Shearing processes Forging Extrusion Deep or Cup drawing Wire and Bar drawing Surface Area / Volume is small Surface Area / Volume is large

  7. Bulk DeformationProcesses 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.

  8. Bulk DeformationProcesses 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.

  9. Bulk DeformationProcesses 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.

  10. Bulk DeformationProcesses 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.

  11. Examples of PrecisionCold Forged Products

  12. Precision Hot Forging of Complex Shapes

  13. Precision Hot Forging of Complex Shapes

  14. Sheet MetalworkingProcesses Bending: It involves straining of metal sheet or plate to take an angle along a (usually) straight axis.

  15. Sheet MetalworkingProcesses 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.

  16. Sheet MetalworkingProcesses Shearing: It involves cutting rather than forming of a metal. A shearing operation cuts the work using a punch and die.

  17. 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

  18. Applications and Products of Metal forming in Macro Scale • Automotive • Aerospace • Appliance • Cookware

  19. 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

  20. Skills Needed for Metal Forming Engineering • Mechanics • Material Science • Manufacturing Process • Design and Control • Machinery • Computer Skills • FEA

  21. 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.

  22. 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?

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