1. Fundamentals of Metal Forming Metal forming includes a large group of manufacturing processes in which plastic deformation is used to change the shape of metal workpieces. Deformation results from the use of a tool, usually called as die in metal forming, which applies stresses that exceeds the yield strength of the metal.

2. Contd… The metal deforms to take the shape determined by the geometry of die. Usually compressive stresses are applied to plastically deform the material. But, some forming processes stretch the metal, while other bends the metal and some other apply shear stresses to the metal.

3. Contd… Certain properties are required to be successfully deformed: a) Low yield strength. b) High ductility. Temperature is the factor in metal working that affects these properties. It increases the ductility and reduces the yield strength.

4. Classification of Metal Forming Bulk deformation processes Sheet metal working processes NOTE : Each category includes several major classes of shaping operations.

5. METAL FORMING ROLLING PROCESSES BENDING OPERATIONS BULK DEFORMATION SHEET METAL WORKING FORGING PROCESSES EXTRUSION PROCESSES SHEARING PROCESSES DEEP OR CUP DRAWING MISCELLANEOUS PROCESSES WIRE AND BAR DRAWING

6. BULK DEFORMATION PROCESSES Rolling:- Compressive deformation process in which the thickness of slab or plate is reduced by two opposing cylindrical tools called as rolls.

7. Contd… Forging :- Workpiece is compressed between two opposing dies, so that dies shapes are imparted to it.

8. Contd… Extrusion :- Compression process in which work metal is forced to flow through a die opening, thus taking the shape of the opening as its own cross-section.

9. Contd… Drawing :- The diameter of a round bar or wire is reduced by pulling it through a die opening.

10. SHEET METAL WORKING PROCESSES Bending :- It involves straining of a metal sheet or plate to take an angle along a straight axis.

11. Contd… Drawing :- refers to the forming of a flat metal sheet into a hollow or concave shape, such as cup, by stretching the metal.

12. Contd… Shearing:- Characterized under sheet metal forming but actually a cutting process.

13. Miscellaneous Spinning Stretch Forming Roll Bending Bending of tube stock NOTE : All are shaping processes but do not use punch or die tooling.