Metal forming processes with analysis

R. Ganesh Narayanan, IITG
Metal forming processes
Metal forming: Large set of manufacturing processes in which the material is deformed
plastically to take the shape of the die geometry. The tools used for such deformation
are called die, punch etc. depending on the type of process.
Plastic deformation: Stresses beyond yield strength of the workpiece material is
required.
Categories: Bulk metal forming, Sheet metal forming
stretching
General classification of metal forming processes
M.P. Groover, Fundamental of modern manufacturing Materials, Processes and systems, 4ed

Classification of basic bulk forming processes
Rolling
Forging
Extrusion
Wire drawing
Rolling: In this process, the workpiece in the form of slab or plate is compressed between two
rotating rolls in the thickness direction, so that the thickness is reduced. The rotating rolls draw
the slab into the gap and compresses it. The final product is in the form of sheet.
Forging: The workpiece is compressed between two dies containing shaped contours. The die
shapes are imparted into the final part.
Extrusion: In this, the workpiece is compressed or pushed into the die opening to take the
shape of the die hole as its cross section.
Wire or rod drawing: similar to extrusion, except that the workpiece is pulled through the die
opening to take the cross-section.
Bulk forming: It is a severe deformation process resulting in massive shape change. The
surface area-to-volume of the work is relatively small. Mostly done in hot working conditions.

Bending: In this, the sheet material is strained by punch to give a bend shape (angle shape)
usually in a straight axis.
Deep (or cup) drawing: In this operation, forming of a flat metal sheet into a hollow or concave
shape like a cup, is performed by stretching the metal in some regions. A blank-holder is used to
clamp the blank on the die, while the punch pushes into the sheet metal. The sheet is drawn into
the die hole taking the shape of the cavity.
Shearing: This is nothing but cutting of sheets by shearing action.
Sheet forming: Sheet metal forming involves forming and cutting operations performed on metal
sheets, strips, and coils. The surface area-to-volume ratio of the starting metal is relatively high.
Tools include punch, die that are used to deform the sheets.
Classification of basic sheet forming processes
Bending Deep drawing shearing

Cold working, warm working, hot working
Cold working: Generally done at room temperature or slightly above RT.
Advantages compared to hot forming:
(1) closer tolerances can be achieved; (2) good surface finish; (3) because of strain
hardening, higher strength and hardness is seen in part; (4) grain flow during
deformation provides the opportunity for desirable directional properties; (5) since no
heating of the work is involved, furnace, fuel, electricity costs are minimized, (6)
Machining requirements are minimum resulting in possibility of near net shaped
forming.
Disadvantages: (1) higher forces and power are required; (2) strain hardening of the
work metal limit the amount of forming that can be done, (3) sometimes cold forming-
annealing-cold forming cycle should be followed, (4) the work piece is not ductile
enough to be cold worked.
Warm working: In this case, forming is performed at temperatures just above room
temperature but below the recrystallization temperature. The working temperature is
taken to be 0.3 Tm where Tm is the melting point of the workpiece.
Advantages: (1) enhanced plastic deformation properties, (2) lower forces required, (3)
intricate work geometries possible, (4) annealing stages can be reduced.

Hot working: Involves deformation above recrystallization temperature,
between 0.5Tm to 0.75Tm.
Advantages: (1) significant plastic deformation can be given to the sample,
(2) significant change in workpiece shape, (3) lower forces are required, (4)
materials with premature failure can be hot formed, (5) absence of
strengthening due to work hardening.
Disadvantages: (1) shorter tool life, (2) poor surface finish, (3) lower
dimensional accuracy, (4) sample surface oxidation

Bulk forming processes
Forging
• It is a deformation process in which the work piece is compressed between two
dies, using either impact load or hydraulic load (or gradual load) to deform it.
• It is used to make a variety of high-strength components for automotive, aerospace,
and other applications. The components include engine crankshafts, connecting rods,
gears, aircraft structural components, jet engine turbine parts etc.
• Category based on temperature : cold, warm, hot forging
• Category based on presses:
impact load => forging hammer; gradual pressure => forging press
• Category based on type of forming:
Open die forging, impression die forging, flashless forging
Open die forging
In open die forging, the work piece is
compressed between two flat platens or dies,
thus allowing the metal to flow without any
restriction in the sideward direction relative to
the die surfaces.

impression die forging
flashless forging
In impression die forging, the die surfaces contain a shape that is given to the work
piece during compression, thus restricting the metal flow significantly. There is some
extra deformed material outside the die impression which is called as flash. This will
be trimmed off later.
In flashless forging, the work piece is fully restricted within the die and no flash is
produced. The amount of initial work piece used must be controlled accurately so
that it matches the volume of the die cavity.

Open die forging
A simplest example of open die forging is compression of billet between two flat die
halves which is like compression test. This also known as upsetting or upset forging.
Basically height decreases and diameter increases.
Under ideal conditions, where there is no friction between the billet and die surfaces,
homogeneous deformation occurs. In this, the diameter increases uniformly
throughout its height.
In ideal condition, ε = ln (ho/h). h will be equal to hf at the end of compression, ε will
be maximum for the whole forming. Also F = σf A is used to find the force required for
forging, where σf is the flow stress corresponding to ε at that stage of forming.
Start of compression Partial compression Completed compression

In actual forging operation, the deformation will not be homogeneous as
bulging occurs because of the presence of friction at the die-billet interface.
This friction opposes the movement of billet at the surface. This is called
barreling effect.
The barreling effect will be significant as the diameter-to-height (D/h) ratio of
the workpart increases, due to the greater contact area at the billet–die
interface. Temperature will also affect the barreling phenomenon.
Start of
compression
Partial
compression
Completed
compression
In actual forging, the accurate force evaluation is done by using, F = Kf σf A by
considering the effect of friction and D/h ratio. Here,
Where Kf = forging shape factor, μ = coefficient of friction, D = work piece diameter, h = work
piece height
h
D
K f
4.0
1

Typical load-stroke curve
in open die forging
Effect of h/D ratio on barreling:
Long cylinder: h/D >2 Cylinder having h/D < 2
with friction
Frictionless compression
µ0
µ1
µ2
D/h
Compression Load
µ2 > µ1
Effect of D/h ratio on load:

Closed die forging
Closed die forging called as impression die forging is performed in dies which has the
impression that will be imparted to the work piece through forming.
In the intermediate stage, the initial billet deforms partially giving a bulged shape.
During the die full closure, impression is fully filled with deformed billet and further
moves out of the impression to form flash.
In multi stage operation, separate die cavities are required for shape change. In the
initial stages, uniform distribution of properties and microstructure are seen. In the final
stage, actual shape modification is observed. When drop forging is used, several blows
of the hammer may be required for each step.
Starting stage Intermediate
stage
Final stage with
flash formation

The formula used for open die forging earlier can be used for closed die
forging, i.e.,
F = Kf σf A
Where F is maximum force in the operation; A is projected area of the part
including flash, σf is flow stress of the material, Kf is forging shape factor.
Now selecting the proper value of flow stress is difficult because the strain
varies throughout the work piece for complex shapes and hence the
strength varies. Sometimes an average strength is used. Kf is used for
taking care of different shapes of parts. Table shows the typical values of Kf
used for force calculation. In hot working, appropriate flow stress at that
temperature is used.
The above equation is applied to find the maximum force during the
operation, since this is the load that will determine the required capacity of
the press used in the forging operation.

Impression die forging is not capable of making close tolerance objects.
Machining is generally required to achieve the accuracies needed. The basic
geometry of the part is obtained from the forging process, with subsequent
machining done on those portions of the part that require precision finishing
like holes, threads etc.
In order to improve the efficiency of closed die forging, precision forging was
developed that can produce forgings with thin sections, more complex
geometries, closer tolerances, and elimination of machining allowances. In
precision forging operations, sometimes machining is fully eliminated which is
called near-net shape forging.

Flashless forging
The three stages of flashless forging is shown below:
In flashless forging, most important is that the work piece volume must
equal the space in the die cavity within a very close tolerance.
If the starting billet size is too large, excessive pressures will cause damage
to the die and press.
If the billet size is too small, the cavity will not be filled.
Because of the demands, this process is suitable to make simple and
symmetrical part geometries, and to work materials such as Al, Mg and their
alloys.

Coining is a simple application of closed die forging in which fine details in the
die impression are impressed into the top or/and bottom surfaces of the work
piece.
Though there is little flow of metal in coining, the pressures required to
reproduce the surface details in the die cavity are at par with other impression
forging operations.
Starting of cycle
Fully compressed Ram pressure
removed and
ejection of part
Making of coin

Forging hammers, presses and dies
Hammers:
Hammers operate by applying an impact loading on the work piece. This is
also called as drop hammer, owing to the means of delivering impact energy.
When the upper die strikes the work piece, the
impact energy applied causes the part to take
the form of the die cavity. Sometimes, several
blows of the hammer are required to achieve
the desired change in shape.
Drop hammers are classified as:
Gravity drop hammers, power drop hammers.
Gravity drop hammers - achieve their energy
by the falling weight of a heavy ram. The force
of the blow is dependent on the height of the
drop and the weight of the ram.
Power drop hammers - accelerate the ram by
pressurized air or steam.
Drop hammers

Presses:
The force is given to the forging billet gradually, and not like impact force.
Mechanical presses: In these presses, the rotating motion of a drive motor
is converted into the translation motion of the ram. They operate by means
of eccentrics, cranks, or knuckle joints. Mechanical presses typically
achieve very high forces at the bottom of the forging stroke.
Hydraulic presses : hydraulically driven piston is used to actuate the ram.
Screw presses : apply force by a screw mechanism that drives the vertical
ram. Both screw drive and hydraulic drive operate at relatively low ram
speeds.
Forging dies:

Parting line: The parting line divides the upper die from the lower die. In other
words, it is the plane where the two die halves meet. The selection of parting
line affects grain flow in the part, required load, and flash formation.
Draft: It is the amount of taper given on the sides of the part required to
remove it from the die.
Draft angles: It is meant for easy removal of part after operation is completed.
3° for Al and Mg parts; 5° to 7° for steel parts.
Webs and ribs: They are thin portions of the forging that is parallel and
perpendicular to the parting line. More difficulty is witnessed in forming the
part as they become thinner.
Fillet and corner radii: Small radii limits the metal flow and increase stresses
on die surfaces during forging.
Flash: The pressure build up because of flash formation is controlled proper
design of gutter and flash land.

Other forging operations
Upset forging:
It is a deformation operation in which a cylindrical work piece is increased in diameter
with reduction in length. In industry practice, it is done as closed die forging.
Upset forging is widely used in the fastener industries to form heads on nails, bolts,
and similar products.
Feeding of work piece
Gripping of work piece and retracting of stop
Forward movement of
punch and upsetting
Forging operation completes

Heading:
The following figure shows variety of heading operations with different die
profiles.
Heading a die using open die forging Round head formed by punch only
Head formed inside die only Bolt head formed by both
die and punch
Long bar stock (work piece) is fed into the machines by horizontal slides, the end of
the stock is upset forged, and the piece is cut to appropriate length to make the
desired product. The maximum length that can be upset in a single blow is three
times the diameter of the initial wire stock.

Swaging:
Swaging is used to reduce the diameter of a tube or a rod at the end of the
work piece to create a tapered section. In general, this process is conducted
by means of rotating dies that hammer a workpiece in radial direction inward
to taper it as the piece is fed into the dies. A mandrel is required to control the
shape and size of the internal diameter of tubular parts during swaging.
Radial forging:
This operation is same as swaging,
except that in radial forging, the dies do
not rotate around the work piece,
instead, the work is rotated as it feeds
into the hammering dies.
Swaging
Diameter reduction of solid work Tube tapering Swaging to form a groove on
the tube
Swaging the edge of a cylinder
Swaging with different die profiles

Roll forging:
It is a forming process used to reduce the cross section of a cylindrical or
rectangular rod by passing it through a set of opposing rolls that have matching
grooves w.r.t. the desired shape of the final part. It combines both rolling and
forging, but classified as forging operation.
Depending on the amount of deformation, the rolls rotate partially. Roll-forged
parts are generally stronger and possess desired grain structure compared to
machining that might be used to produce the same part.

Orbital forging:
In this process, forming is imparted to the workpiece by means of a cone-
shaped upper die that is simultaneously rolled and pressed into the work.
The work is supported on a lower die.
Because of the inclined axis of cone, only a small area of the work surface is
compressed at any stage of forming. As the upper die revolves, the area
under compression also revolves. Because of partial deformation contact at
any stage of forming, there is a substantial reduction in press load
requirement.

Isothermal forging:
It is a hot-forging operation in which the work is maintained at some
elevated temperature during forming. The forging dies are also maintained
at the same elevated temperature. By avoiding chill of the work in contact
with the cold die surfaces, the metal flows more readily and the force
requirement is reduced.
The process is expensive than conventional forging and is usually meant for
difficult-to-forge metals, like Ti, superalloys, and for complex part shapes.
The process is done in vacuum or inert atmosphere to avoid rapid oxidation
of the die material.

Extrusion
Extrusion is a bulk forming process in which the work metal is forced or
compressed to flow through a die hole to produce a desired cross-sectional
shape. Example: squeezing toothpaste from a toothpaste tube.
Advantages :
- Variety of shapes are possible, especially using hot extrusion
- Grain structure and strength properties are enhanced in cold and warm
extrusion
- Close tolerances are possible, mainly in cold extrusion
Types of extrusion:
Direct or forward extrusion, Indirect or backward extrusion
Direct extrusion: - A metal billet is first loaded into a container having die
holes. A ram compresses the material, forcing it to flow through the die holes.
- Some extra portion of the billet will be present at the end of the process that
cannot be extruded and is called butt. It is separated from the product by
cutting it just beyond the exit of the die.

Direct extrusion
- In direct extrusion, a significant amount of friction exists between the billet
surface and the container walls, as the billet is forced to slide toward the die
opening. Because of the presence of friction, a substantial increase in the ram
force is required.
- In hot direct extrusion, the friction problem is increased by the presence of
oxide layer on the surface of the billet. This oxide layer can cause defects in
the extruded product.
- In order to address these problems, a dummy block is used between the ram
and the work billet. The diameter of the dummy block is kept slightly smaller
than the billet diameter, so that a thin layer of billet containing the oxide layer is
left in the container, leaving the final product free of oxides.

Hollow sections like tubes can be made using direct extrusion setup shown in
above figure. The starting billet is prepared with a hole parallel to its axis. As
the billet is compressed, the material will flow through the gap between the
mandrel and the die opening.
Indirect extrusion: - In this type, the die is mounted to the ram and not on the
container. As the ram compresses the metal, it flows through the die hole on
the ram side which is in opposite direction to the movement of ram.
- Since there is no relative motion between the billet and the container, there is
no friction at the interface, and hence the ram force is lower than in direct
extrusion.
- Limitations: lower rigidity of the hollow ram, difficulty in supporting the
extruded product at the exit
Making hollow shapes using direct
extrusion

Indirect extrusion: solid billet and hollow billet
Simple analysis of extrusion
Pressure distribution and billet dimensions in direct extrusion

Assuming the initial billet and extrudate are in round cross-section. An
important parameter, extrusion ratio (re), is defined as below:
True strain in extrusion under ideal deformation (no friction and redundant
work) is given by,
Under ideal deformation, the ram pressure required to extrude the billet
through die hole is given by,
where
f
e
A
A
r 0

A0 - CSA of the initial billet
Af - CSA of the extruded section
)ln()ln( 0
f
e
A
A
r 
)ln()ln( 0
f
fef
A
A
YrYp 
n
K
Y
n
f


1

Note: The average flow stress is found out
by integrating the flow curve equation
between zero and the final strain defining
the range of forming
Where Yf is average flow stress, and is maximum strain value during the
extrusion process.
The actual pressure for extrusion will be greater than in ideal case, because
of the friction between billet and die and billet and container wall.


There are various equations used to evaluate the actual true strain and
associated ram pressure during extrusion. The following relation proposed
by Johnson is of great interest.
Where is extrusion strain; a and b are empirical constants for a given die
angle. Typical values are: a = 0.8, b = 1.2 - 1.5.
In direct extrusion, assuming that friction exists at the interface, we can find
the actual extrusion pressure as follows:
billet-container friction force = additional ram force to overcome that
friction
The above eqn. assume sliding friction condition. Assuming sticking friction at the
interface, we can write:
 barba ex  ln
x
4
2
0
0
Dp
LDp
f
e

 
Where pf is additional pressure
required to overcome friction, pe is
pressure against the container wall
4
2
0
0
Dp
LDK
f 
  Where K is shear yield strength & m = 1
xfYp 

The above eqn. gives,
Assuming, we get,
This is the additional pressure required to
overcome friction during extrusion.
Now the actual ram pressure required for
direct extrusion is given by,
L is the billet length remaining to be extruded,
and D0 is the initial diameter of the billet. Here
p is reduced as the remaining billet length
decreases during the extrusion process.
Ram pressure variation with stroke for direct
and indirect extrusion is shown in Figure.
0
4
D
KL
p f 
2
fY
K 
0
2
D
L
Yp ff 







0
2
D
L
Yp xf 
The shape of the initial pressure build up
depends on die angle. Higher die angles
cause steeper pressure buildups.

Sliding friction
p 
Sticking friction
mK

p

A billet 75 mm long and 25 mm in diameter is to be extruded in a direct
extrusion operation with extrusion ratio re = 4.0. The extrudate has a round
cross section. The die angle (half angle) is 90°. The work metal has a
strength coefficient of 415 MPa, and strain-hardening exponent of 0.18.
Use the Johnson formula with a = 0.8 and b=1.5 to estimate extrusion strain.
Find the pressure applied to the end of the billet as the ram moves forward.

Empirical formulae for extrusion pressure
Hot extrusion of Al alloys:
For extrusion of pure Al, Al-Zn alloy, Al-Zn-Mg alloy in the temperature range of 50-
500°C.
Cold extrusion of steel:
Rpe ln32.152.0/ 0  for values of R from 1 to 100
Rpe ln78.413/ 0  for values of R from 100 to 1000
Here R = 1/(1-r)
where ‘r’ is the
relative reduction
in area
2
375.0787.0
)2()(262.0
mm
N
AFp re  100
1
21


A
AA
leadofstrengthYield
steelofstrengthYield
F 
Where Ar = percent reduction in area =
B.L.Juneja, Fundamental of metal forming processes,2ed

Extrusion dies
- Two important factors in an extrusion die are: die angle, orifice shape.
- For low die angles, surface area of the die is large, resulting in increased
friction at the die-billet interface. Higher friction results in higher ram force.
- For a large die angle, more turbulence in the metal flow is caused during
reduction, increasing the ram force required.
- The effect of die angle on ram force is a U-shaped function, shown in
Figure. So, an optimum die angle exists. The optimum angle depends on
various factors like work material, billet temperature, and lubrication.

- The extrusion pressure eqns. derived earlier are for a circular die orifice.
- The shape of the die orifice affects the ram pressure required to perform an
extrusion operation, as it determines the amount of squeezing of metal billet.
-The effect of the die orifice shape can be assessed by the die shape factor,
defined as the ratio of the pressure required to extrude a cross section of a
given shape relative to the extrusion pressure for a circular cross section of
the same area.
25.2
02.098.0 






c
x
x
c
c
k
Where kx is the die shape factor in extrusion; Cx is the perimeter of the
extruded cross section, and Cc is the perimeter of a circle of the same area as
the actual extruded shape.
varies from 1 to 6.
c
x
c
c

Die materials
For hot extrusion - tool and alloy steels.
Important properties of die materials are high wear resistance, high thermal
conductivity to remove heat from the process.
For cold extrusion - tool steels and cemented carbides.
Carbides are used when high production rates, long die life, and good
dimensional control are expected.

Other extrusion processes
Impact extrusion:
- It is performed at higher speeds and shorter strokes. The billet is extruded
through the die by impact pressure and not just by applying pressure.
- But impacting can be carried out as forward extrusion, backward extrusion,
or combination of these.
forward extrusion Backward extrusion
combined extrusion

- Impact extrusion is carried out as cold forming. Very thin walls are possible
by backward impact extrusion method. Eg: making tooth paste tubes,
battery cases.
- Advantages of IE: large reductions and high production rates
Hydrostatic extrusion:
Hydrostatic extrusion

In hydrostatic extrusion, the billet is surrounded with fluid inside the
container and the fluid is pressurized by the forward motion of the ram.
There is no friction inside the container because of the fluid, and friction is
minimized at the die opening. If used at high temperatures, special fluids
and procedures must be followed.
Hydrostatic pressure on the work and no friction situation increases the
material’s ductility. Hence this process can be used on metals that would
be too brittle for conventional extrusion methods.
This process is also applicable for ductile metals, and here high reduction
ratios are possible.
The preparation of starting work billet is important. The billet must be
formed with a taper at one end to fit tightly into the die entry angle, so that
it acts as a seal to prevent fluid leakage through die hole under pressure.

Defects during extrusion
Centerburst:
- This is an internal crack that develops as a result of tensile
stresses along the center axis of the workpiece during
extrusion. A large material motion at the outer regions pulls
the material along the center of the work. Beyond a critical
limit, bursting occurs.
- Conditions that promote this defect are: higher die angles,
low extrusion ratios, and impurities in the work metal. This is
also called as Chevron cracking.
Piping: It is the formation of a sink hole in the end of the
billet. This is minimized by the usage of a dummy block
whose diameter is slightly less than that of the billet.
Surface cracking: This defect results from high workpiece
temperatures that cause cracks to develop at the surface.
They also occur at higher extrusion speeds, leading to high
strain rates and heat generation. Higher friction at the
surface and surface chilling of high temperature billets in hot
extrusion also cause this defect.
Centerburst
Piping
Surface cracking

Wire, rod, bar drawing
- In this bulk forming process, a wire, rod, bar are pulled through a die hole
reducing their cross-section area.
Difference between wire drawing and rod drawing:
Initial stock size:
- The basic difference between bar drawing and wire drawing is the stock size
that is used for forming. Bar drawing is meant for large diameter bar and rod,
while wire drawing is meant for small diameter stock. Wire sizes of the order
of 0.03 mm are produced in wire drawing.
Wire, rod, bar drawing

Operating stages:
- Bar drawing is generally done as a single stage operation, in which stock
is pulled through one die opening. The inlet bars are straight and not in the
form of coil, which limits the length of the work that can be drawn. This
necessitates a batch type operation.
- In contrast, wire is drawn from coils consisting of several hundred meters
of wire and is drawn through a series of dies. The number of dies varies
between 4 and 12. This is termed as ‘continuous drawing’ because of the
long production runs that are achieved with the wire coils. The segments
can be butt-welded to the next to make the operation truly continuous.

Simple analysis of wire drawing
True strain in wire drawing under ideal deformation (no friction and redundant work)
is given by,
Under ideal deformation, the stress required in wire drawing is given by,
)
1
1
ln()ln( 0
rA
A
f 
 Here r = (A0 – Af) / A0
Here , is the average flow stress
corresponding to ε mentioned in above equation.
)ln( 0
f
fd
A
A
Y
n
K
Y
n
f


1

fY
In order to consider the effect of die angle and friction coefficient on the drawing
stress, Schey has proposed another equation as shown below:
)ln(
tan
1 0
f
fd
A
A
Y 


 







sin2
;
2
00 f
C
f DD
L
DD
D




Here is a term that accounts for inhomogeneous deformation which is found
by the following eqn. for round cross-section.

cL
D
12.088.0  Here D is the average diameter of the workpiece, LC is the
contact length of the work with die given by,
Finally the drawing force is given by, F = Afσd
Wire is drawn through a draw die with entrance angle 15°. Starting diameter is 2.5 mm
and final diameter 2 mm. The coefficient of friction at the work–die interface is 0.07.
The metal has a strength coefficient K = 205 MPa and a strain-hardening exponent n =
0.2. Determine the draw stress and draw force in this operation.
The power required for drawing is given
by multiplying drawing force with exit
velocity of the workpiece

Maximum reduction per pass
Increase in reduction, increase the draw stress. If the reduction is large
enough, draw stress will exceed the yield strength of the material. Then the
wire will just elongate rather than new material being drawn into the die
hole. To have a successful wire drawing operation, drawing stress should be
less than yield strength of the drawn metal.
Assume a perfectly plastic material (n = 0), no friction and redundant work,
then,
which means that
This gives a condition that the maximum possible reduction, rmax is
rmax = 0.632 (theoretical maximum limit)
This analysis ignores the effects of friction and redundant work, which would further reduce the
maximum value, and strain hardening, which would increase the maximum reduction because
of the stronger wire than the starting metal. Reductions of 0.5-0.3 per pass seem to be
possible in industrial operations.
Y
r
Y
A
A
Y
A
A
Y
ff
fd 

 )
1
1
ln()ln()ln( 00

1)
1
1
ln()ln( 0



rA
A
f

Drawing equipment
Drawing bar by draw
bench
Continuous drawing of
wire

Drawing dies
The entry region is generally a bell-shaped
mouth that does not contact the work-
piece. Its function is to contain and push
the lubricant into the die and prevent
wearing of work and die surfaces
The approach region is where the drawing
operation occurs. It is cone-shaped with an angle
(half-angle) normally ranging from 6° to 20°.
The bearing surface or land, determines the size of the final drawn work-piece.
Finally, the back relief is the exit zone. It is provided with a back relief angle (half-angle) of
about 25-30°.

Tube drawing
This operation is used to reduce the diameter or wall thickness of the seamless tubes
and pipes. Tube drawing can be done either with or without mandrel. The simplest
method uses no mandrel and is used for diameter reduction called as tube
sinking. But inside diameter and wall thickness cannot be controlled. So mandrel is
required.
Die
Die
Mandrel
Rod
Tube
Die Tube
Pull force
Die Tube
Pull force
Floating mandrel
(a) Rod drawing (c) Tube drawing with fixed mandrel
(b) Tube drawing without mandrel (d) Tube drawing with floating mandrel
(TUBE SINKING)

Using a fixed mandrel: In this case, a mandrel is attached to a long support
bar to control the inside diameter and wall thickness during the operation.
The length of the support bar restricts the length of the tube that can be
drawn.
Using a floating plug: As the name suggests the mandrel floats inside the
tube and its shape is designed so that it finds a suitable position in the
reduction zone of the die. There is no length restriction in this as seen with
the fixed mandrel.

Rolling
Rolling is a metal forming process in which the thickness of the work is reduced by
compressive forces exerted by two rolls rotating in opposite direction. Flat rolling is
shown in figure. Similarly shape rolling is also possible like a square cross section is
formed into a shape such as an I-beam, L-beam.
Important terminologies:
Bloom: It has a square cross section 150 mm x 150 mm or more.
Slab: It is rolled from an ingot or a bloom and has a rectangular cross section of 250
mm width or more and thickness 40 mm or more.
Billet: It is rolled from a bloom and is square in cross-section with dimensions 40mm
on a side or more.
Flat rolling

Blooms are rolled into structural shapes like rails for railroad tracks.
Billets are rolled into bars, rods. They become raw materials for machining,
wire drawing, forging, extrusion etc.
Slabs are rolled into plates, sheets, and strips. Hot rolled plates are generally
used in shipbuilding, bridges, boilers, welded structures for various heavy
machines, and many other products.

The plates and sheets are further reduced in thickness by cold rolling to
strengthen the metal and permits a tighter tolerance on thickness.
Important advantage is that the surface of the cold-rolled sheet does not
contain scales and generally superior to the corresponding hot rolled
product.
Later the cold-rolled sheets are used for stampings, exterior panels, and
other parts used in automobile, aerospace and house hold appliance
industries.

Simple analysis of flat strip rolling
The schematic of flat rolling is shown in previous slides. It involves rolling of
sheets, plates having rectangular cross section in which the width is greater
than the thickness.
In flat rolling, the plate thickness is reduced by squeezing between two rolls.
The thickness reduction is quantified by draft which is given by,
d = t0 – tf
here t0 and tf are initial thickness and final thickness of the sheet used for
rolling.
Draft is also defined as, r = d / t0 . Here r is reduction.
During rolling, the workpiece width increases which is termed as spreading.
It will be large when we have low width to thickness ratio and low friction
coefficient.
In strip rolling, and hence
Here wo and wf are the initial and final work widths, l0 and lf are the initial and final work lengths.
vo and vf are the entry and exit velocities of the work.
fff lwtlwt 000 fff vwtvwt 000

In strip rolling, the width will not change much after rolling. From the
previous equation, it is observed that the exit velocity vf is greater than
entry velocity v0. In fact, the velocity of the rolled sheet continuously
increases from entry to exit.
The rolls contact the rolling sheet along an arc
defined by angle θ. Each roll has radius R, and
its has surface velocity vr. This velocity is in
between entry and exit velocity.
However, there is one point or zone along the
contact arc where work velocity equals roll
velocity. This is called the no-slip point, or neutral
point.
On either side of the neutral point, slipping and
friction occur between roll and sheet. The
amount of slip between the rolls and the sheet
can be quantified by forward slip, S,
r
rf
v
vv
S

 vf is the final velocity, vr is the roll velocity

The true strain during rolling is given by,
The true strain is used to find the average flow stress (Yf) and further rolling
power, force.
On the entry side of the neutral point, friction force is in one direction, and on
the other side it is in the opposite direction, i.e., the friction force acts towards the
neutral point. But the two forces are unequal.
The friction force on the entry side is greater, so that the net force pulls the sheet
through the rolls. Otherwise, rolling would not be possible.
The limit to the maximum possible draft that can be accomplished in flat rolling is
given by,
The equation indicates that if friction were zero, draft is zero, and it is not possible
to accomplish the rolling operation.
)ln( 0
ft
t

n
K
Y
n
f


1

Rd 2
max 

The friction coefficient in rolling depends on lubrication, work material, and
working temperature.
In cold rolling, the value is app. 0.1, in warm rolling, a typical value is around
0.2; and in hot rolling, it is around 0.4.
Hot rolling is characterized by sticking friction condition, in which the hot
work surface adheres to the rolls over the contact region. This condition often
occurs in the rolling of steels and high-temperature alloys.
When sticking occurs, the coefficient of friction can be as high as 0.7.
The roll force (F) is calculated by, , wL is the contact area
The contact length (projected) is approximated by,
The rolling power required for two powered rolls is given by, P = (2πN)FL (watts)
wLYF f
)( 0 fttRL 

Typical variation in roll pressure along the contact length in flat rolling
Area under the curve,
rolling force, F, 
L
pdLwF
0

A 300 mm wide strip, 25 mm thick, is fed through a rolling mill with two powered rolls
each of radius 250 mm. The work thickness is to be reduced to 22 mm in one pass at a
roll speed of 50 rev/min. The work material has a flow curve defined by K = 275 MPa and
n = 0.15, and the coefficient of friction between the rolls and the work is 0.12. Determine if the
friction is sufficient to permit the rolling operation to be accomplished. If so, calculate the roll
force, and horsepower (or rolling power).
Inference from equations: The strip rolling force and/or power of a given width and work
material can be reduced by the following methods: (1) using hot rolling rather than cold rolling to
reduce strength and strain hardening (K and n) of the work material; (2) reducing the draft in
each rolling pass; (3) using a smaller roll radius ‘R’ to reduce force; and (4) using a lower rolling
speed ‘N’ to reduce power.

Rolling mills
Two high rolling mill: This type of rolling mill consists of two rolls rotating in
opposite directions.
Roll diameters: 0.6 to 1.4 m
Types: either reversing or non-reversing.
Non-reversing mill: rolls rotate only in one direction, and the slab always
move from entry to exit side.
Reversing mill: direction of roll rotation is reversed, after each pass, so that
the slab can be passed through in both the directions. This permits a
continuous reductions to be made through the same pairs of rolls.
Two high rolling mill

Three high rolling mill: In this case, there are three
rolls one above the other. At a time, for single pass,
two rolls will be used. The roll direction will not be
changed in this case.
The top two rolls will be used for first reduction and
the sheet is shifted to the bottom two rolls and
further reduction is done. This cycle is continued till
actual reduction is attained.
Disadvantage: automated mechanism is required to
shift the slab Three high rolling mill
Four high rolling mill
Four high rolling mill: This consists of two small rolls for
thickness reduction and two large backing rolls to
support the small rolls.
The small rolls will reduce the roll force required as the
roll-sheet contact area will be reduced.
The large backing rolls are required to reduce the elastic
deflection of small rolls when sheet passes between
them.

Cluster rolling mill
Cluster rolling mill: This uses smaller rolls for rolling
Tandem rolling mill
Tandem rolling mill:
This consists of series of rolling stations of the order of 8 to 10. In each
station, thickness reduction is given to the sheet. With each rolling station,
the work velocity increases.
This is fully used in industry practice, along with continuous casting
operation. This results in reduction in floor space, shorter manufacturing lead
time.

Thread rolling
Thread rolling is used to create threads on cylindrical parts by rolling them between
two dies as shown in figure.
It is used for mass production of external threaded parts like bolts and screws.
Ring rolling is a forming process in which a thick walled ring part of smaller diameter
is rolled into a thin walled ring of larger diameter.
As the thick walled ring is compressed, the deformed material elongates, making the
diameter of the ring to be enlarged.
Application: ball and roller bearing races, steel tires for railroad wheels, rings for
pipes, pressure vessels, and rotating machinery
Ring rolling

Start of process (thick
walled, small diameter)
Completion of process
(thin walled, large
diameter)
Ring rolling

Defects in strip rolling
Waviness
Cracking Edge defect
Light reduction Heavy reduction
Aligatoring
G.E.Dieter, Mechanical Metallurgy

Sheet forming operations
Sheet forming:
Involves plastic deformation of sheets like deep drawing, cutting, bending,
hemming, flanging, curling, stretch forming/stretching, stamping etc.
V-bending Edge bending
shearing

Straight flanging stretch flanging shrink flanging
Hemming seaming curling

Other bending operations
Cup deep drawing

Cup deep drawing
It is a sheet forming operation, in which the sheet is placed over the die
opening and is pushed by punch into the opening. The sheet is held flat on
the die surface by using a blank holder.
c – clearance
Db – blank diameter
Dp – punch diameter
Rd – die corner radius
Rp – punch corner radius
F – drawing force
Fh – holding force
Stages in deep drawing:
(i) As the punch pushes the sheet, it is subjected to a bending operation. Bending of
sheet occurs over the punch corner and die corner. The outside perimeter of the blank
moves slightly inwards toward the cup center.
The clearance ‘c’ is defined to equal to 10% more than the sheet thickness ‘t’. If the
clearance between the die and the punch is less than the sheet thickness, then
ironing occurs.
tc 1.1

(ii) In this stage, the sheet region that was bent over the die corner will be straightened
in the clearance region at this stage, so that it will become cup wall region. In order to
compensate the presence of sheet in cup wall, more metal will be pulled from the
sheet edge, i.e., more metal moves into the die opening.
(iii) Friction between the sheet and the die, blank holder surfaces restricts the
movement of sheet into the die opening. The blank holding force also influences the
movement. Lubricants or drawing compounds are generally used to reduce friction
forces.
(iv) Other than friction, compression occurs at the edge of the sheet. Since the
perimeter is reduced, the sheet is squeezed into the die opening. Because volume
remains constant, with reduction in perimeter, thickening occurs at the edge.
In thin sheets, this is reflected in the form of wrinkling. This also occurs in case of low
blank holding force. If BHF very small, wrinkling occurs. If it is high, it prevents the
sheet from flowing properly toward the die hole, resulting in stretching and tearing of
sheet.
(v) The final cup part will have some thinning in side wall.

Stages in cup deep drawing

Punch force-stroke for cup deep drawing:
contribution from three important factors
Increases with increase in strain
because of strain hardening
Friction force reaches peak early and
then decreases as the contact area
decreases between the sheet and BH
Ironing occurs late in the
process once the cup wall has
reached the maximum thickness
G.E.Dieter, Mechanical Metallurgy

Quantification of cup drawability
Drawing ratio: ratio of blank diameter, Db, to punch diameter, Dp. The greater
the ratio, the more severe the drawing operation.
P
b
D
D
DR 
The limiting value for a given operation depends on punch and die corner
radii, friction conditions, draw depth, and quality of the sheet metal like
ductility, degree of directionality of strength properties in the metal.
Reduction, R, is defined as,
Limiting values: DR ≤ 2; R ≤ 0.5
Thickness to diameter ratio, t/Db > 1%;
As the ratio decreases, tendency for wrinkling increases.
b
Pb
D
DD
R



The maximum drawing force, F , can be estimated approximately by the
following equation .








 7.0
p
b
UTSp
D
D
tDF 
Correction factor for friction
The holding force, Fh, is given by,
  22
22.2015.0 dpbysh RtDDF  
3
F
Fh  (approx. holding force is one-third of drawing force)

A cup drawing operation is performed in which the inside diameter = 80 mm and
the height = 50 mm. The stock thickness = 3 mm, and the starting blank diameter
= 150 mm. Punch and die radii = 4 mm. Tensile strength = 400 MPa and a yield
strength = 180 MPa for this sheet metal. Determine: (a) drawing ratio, (b)
reduction, (c) drawing force, and (d) blankholder force.

Redrawing
In many cases, the shape change involved in making that part will be severe
(drawing ratio is very high). In such cases, complete forming of the part
requires more than one deep drawing step.
Redrawing refers to any further drawing steps that is required to complete
the drawing operation.
Guidelines for successful redrawing:
First draw: Maximum reduction of the starting blank - 40% to 45%
Second draw: 30%
Third draw : 16%
Redrawing

Reverse redrawing
In reverse redrawing, the sheet part will
face down and drawing is completed in
the direction of initial bend.
Drawing without blank holder
The main function of BH is to reduce wrinkling.
The tendency of wrinkling decreases with increase
in thickness to blank diameter ratio (t/Db). For a
large t/Db ratio, drawing without blank holder is
possible.
The die used must have the funnel or cone shape
to permit the material to be drawn properly into the
die cavity.
Limiting value for drawing without BH:
Db - Dp = 5t

R. Ganesh Narayanan,
IITG
Plastic anisotropy
The main cause of anisotropy of plastic properties is the preferred orientation of
grains, i.e., tendency for grains to have certain orientations. This is cause mainly by
mechanical forming of metals.
A useful parameter to quantify anisotropy is R, the plastic strain ratio, which is the
ratio of true plastic strain in width direction to that in thickness direction. Higher R,
large resistance to thinning.
In many sheet forming operations like deep drawing, the materials exhibit some
anisotropy in the sheet plane. So averaging is done to find a value quantifying all the
variations in the sheet surface as given by the following equation. But this is
practically impossible.
Usually the following equation is used by considering orthotropy is accurate.
t
w
R


 For isotropic materials, R = 1; for anisotropic materials: R > 1 or R < 1




360
0


 dRR
4
2 90450 RRR
R

 (normal anisotropy)
(Average plastic strain ratio)

Another parameter that takes care of planar anisotropy is ∆R given by,
2
2 45900 RRR
R


This is a measure of how different the 45°
directions are from the symmetry axes.

Defects in deep drawing
wrinkling in flange and cup wall tearing earing surface scratches
Wrinkling in flange and cup wall: This is like ups and downs or waviness that is developed on
the flange. If the flange is drawn into the die hole, it will be retained in cup wall region.
Tearing: It is a crack in the cup, near the base, happening due to high tensile stresses causing
thinning and failure of the metal at this place. This can also occur due to sharp die corner.
Earing: The height of the walls of drawn cups have peaks and valleys called as earing. There
may be more than four ears. Earing results from planar anisotropy (∆R), and ear height and
angular position correlate well with the angular variation of R.
Surface scratches: Usage of rough punch, dies and poor lubrication cause scratches in a
drawn cup.

Sheet bending
Sheet bending is defined as the straining of the metal around a straight axis as
shown in figure. During bending operation, the metal on the inner side of the neutral
plane is compressed, and the metal on the outer side of the neutral plane is
stretched. Bending causes no change in the thickness of the sheet metal.
In V-bending, the sheet metal is bent between a V-shaped punch and die set up. The
included angles range from very obtuse to very acute values.
In edge bending, cantilever loading of the sheet is seen. A pressure pad is used to apply a
force to hold the sheet against the die, while the punch forces the sheet to yield and bend
over the edge of the die.
α

l0
A0 B0
C0 D0
t
y
A
B
C D
ρ
θ
Deformation during bending
)1()1()(


y
l
y
yl s 
ba
s y
l
l
l
l


 





 1lnlnln
00
1
For our analysis, it may be assumed that a plane normal section in the sheet will
remain plane and normal and converge on the center of curvature as shown in
Figure. The line A0B0 at the middle surface may change its length to AB, if the sheet
is under stretching during bending. The original length lo becomes, ls = ρθ. A line
C0D0 at a distance y from the middle surface will deform to a length,
where ρ is the radius of curvature.
The axial strain of the fiber CD is,
Marciniak, Duncan, Hu, Mechanics of sheet metal forming
(1)

where ‘εa’ and ‘εb’ are the strains at the middle surface and bending strain
respectively.
In the case of bending with radius of curvature larger compared to the thickness,
the bending strain is approximated as,


yy
b 





 1ln
y
t/
2
t/
2
sheet
Strain distribution in
bending
y
Typical stress distribution
in bending

Choice of material model
For the strain distribution given by equation (1) for bending, the stress distribution on
a section can be found out by knowing a stress-strain law.
Generally elastic-plastic strain hardening behavior is seen in sheet bending. But
there are other assumptions also.
Elastic, perfectly plastic model: Strain hardening may not be important for a bend
ratio (ρ/t) (radius of curvature/thickness) of about 50. For this case the stress-strain
behavior is shown in Figure below.
σ1
ε1
E’ = plane strain modulus of
elasticity
Bending can be seen as plane strain
deformation as strain along bend can be zero
For elastic perfectly plastic model, for stress
less than plane strain yield stress, S,
σ1 = E’ ε1 where E’ = E/1-γ2
For strains greater than yield strains, σ1 = S where S = σf (2/√3)

Rigid, perfectly plastic model: For smaller radius bends, where elastic springback is
not considered, the elastic strains and strain hardening are neglected. So,
σ1 = S σ1
ε1
s
Strain hardening model: When the strains are large, elastic strains can be
neglected, and the power hardening law can be followed.
σ1 = K’ ε1
n
σ1
ε1
σ1 = K’ ε1
n

•Spring back occurs because of the variation in bending stresses across
the thickness, i.e., from inner surface to neutral axis to outer surface. The
tensile stresses decrease and become zero at the neutral axis.
•Since the tensile stresses above neutral axis cause plastic deformation,
the stress at any point (say ‘A’) in the tensile stress zone should be less
than the ultimate tensile strength in a typical tensile stress-strain behavior.
The outer surface will crack, if the tensile stress is greater than ultimate
stress during bending.
•The metal region closer to the neutral axis has been stressed to values
below the elastic limit. This elastic deformation zone is a narrow band on
both sides of the neutral axis, as shown in Fig. The metal region farther
away from the axis has undergone plastic deformation, and obviously is
beyond the yield strength.
•Upon load removal after first bending, the elastic band tries to return to the
original flat condition but cannot, due to the restriction given by the plastic
deformed regions. Some return occurs as the elastic and plastic zones
reach an equilibrium condition and this return is named as spring back.
Spring back

Neutral axis
Zero
Tensile
stress, A
Elastic limit
Yield strength
UTS
Failure
A
σ
ε
Changing stress patterns in a bend
Zone deformed plastically
because of compression
Zone deformed plastically
because of tensionElastic Zone
Neutral axis
Elastic and plastic deformation zones during bending Springback
ASM handbook, sheet metal forming

• Sprinback can be minimized by overbending, bottoming and stretch
forming.
• In overbending, the punch angle and radius are made smaller than the
specified angle on the final part so that the sheet metal springs back to
the desired value.
• Bottoming involves squeezing the part at the end of the stroke, thus
plastically deforming it in the bend region.
Spring back is defined by the equation:
tool
tool
SB

 

'

Stretching/stretch forming
- Stretch forming is a sheet metal forming
process in which the sheet metal is intentionally
stretched and simultaneously bent to have the
shape change.
-The sheet is held by jaws or drawbeads at both
the ends and then stretched by punch, such that
the sheet is stressed above yield strength.
- When the tension is released, the metal has
been plastically deformed. The combined effect
of stretching and bending results in relatively
less springback in the part.
Stretching/stretch forming
Photo from public resource

Forming limit diagram (FLD)
Major strain
Minor strain
safe
failure
Forming limit curve
Bi-axial stretching
strainpath
Plane-strain
strainpath
Deep drawing
strainpath
- Limit strain
Minor strain
Major strain

From tensile test we get only ductility, work
hardening exponent, but it is in a uniaxial tension
without friction, which cannot truly represent
material behaviours obtained from actual sheet
forming operations.
In sheet forming, mainly in stretching, FLD gives
quantification about formability of sheet material.
It tells about quality of the material.
In this diagram, forming limit curve (FLC), plotted
between major strain (in Y-axis) and minor strain
(in X-axis), is the index that says the amount of
safe strains that can be incorporated into the
sheet metal.
The FLC is the locus of all the limit strains in
different strain paths (like deep drawing, biaxial
stretching, plane strain) of the sheet material.
The plane-strain condition possesses the least
forming limit, when compared to deep drawing
and stretching strain paths.
A sheet material with higher
forming limit is considered good.

Metal forming processes with analysis

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