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Dr. Amr Shehata Fayed

Fundamentals of MetalForming Processes

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

Materials Engineering Department

Faculty of EngineeringZagazig University

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Shaping: usuallyinvolves molding and

casting.

Ex. The white ceramicinsulator for a sparkplug of a car body for

a car (clay molding,drying and firing)

Forming and Shaping

Forming: meanschanging the shape of 

an existing solid body.

Ex. The metal body fora car (sheet metalforming)

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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 appliesstresses that exceed the yield strength of the

metal.

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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)

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Bulk Deformation:

Compressive deformation force.

Significant deformations.

Massive shape changes.

Starting work shapes include

billets and rectangular bars.

Surface area / volume is small.

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.

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Surface

 Area /

Volumeis large

Bending

operations

Shearing

processes

Deep or Cup

drawing

Sheet

MetalworkingSurface

 Area /

Volumeis small

Rolling

Forging

Extrusion

Wire and Bar 

drawing

Bulk

Deformation

Metal Forming Processes

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Rolling:  A compressive deformation process in

which the thickness of slab or plate is reduced bytwo opposing tools “rolls”. They rotate to draw the

work piece into the gap between them and

squeeze it.

Bulk Deformation Processes

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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.

Bulk Deformation Processes

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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.

Bulk Deformation Processes

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Drawing:  The work metal is being pulled through adie opening to reduce the diameter of a wire or a bar.

See Fig. Wire Drawing .

Bulk Deformation Processes

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Examples of Precision

Cold Forged Products

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Precision Hot Forging of 

Complex Shapes

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Precision Hot Forging of 

Complex Shapes

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Bending: It involves straining of metal sheet or plate

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

Sheet Metalworking Processes

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

metal sheet into a hollow or concave shape, such ascup, by stretching the metal. A blank holder is used

to hold down the blank while the punch pushes into

the sheet metal.

Sheet Metalworking Processes

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Shearing: It involves cutting rather than forming of 

a metal. A shearing operation cuts the work using a

punch and die.

Sheet Metalworking Processes

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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

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Applications and Products of 

Metal forming in Macro Scale•  Automotive

• Aerospace•  Appliance

• Cookware

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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

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Skills Needed for Metal

Forming Engineering• Mechanics

• Material Science

• Manufacturing Process• Design and Control

• Machinery

• Computer Skills• FEA

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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.

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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?