Advanced

Manufacturing
Process
 Forming Processes

Cost Production Rate

Control
Manufacturing Philosophy
Quality Repeatability
Process Complexity

Casting
Mould/Die

Raw material Molten Metal

Product

Forming
 Forming Processes
Theory of Metal Forming

Mechanical properties of materials: Plasticity and Elasticity

Behaviour of materials under applied load: Deformation behaviour

Thermal properties of materials: Thermal stresses, thermal deformation

Understanding of material: System/Tool development Process

Physical properties & Metallurgical development
Properties

Rolling Forging Drawing Spinning Extrusion

Is casting a forming process ?

 Advanced Forming Processes

• Limitations of the existing forming processes either in materials perspective or in process perspective

• Need of the society/customers

• Design requirements

• Production capacity

• Challenging environment
 Advanced Forming Processes

Ring Rolling Process

• 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.
• Ball and roller bearing races, steel tires for railroad wheels, rings for pipes, pressure vessels, and
rotating machinery
 Advanced Forming Processes

Thread Rolling Process

• 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.
 Advanced Forming Processes

Heading Process

• 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.
 Advanced Forming Processes

Roll forging Process

• 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 with respect 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.

 Advanced Forming Processes

Roll forging Process

 Advanced Forming Processes

Orbital forging Process

• 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.
 Advanced Forming Processes

Orbital forging Process

 Advanced Forming Processes

Stretch forming Process

• 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 draw beads 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 spring back in the part.
 Advanced Forming Processes

Stretch forming Process

 Advanced Forming Processes

Isothermal forging Process

• 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, super alloys, and for complex part shapes.
• The process is done in vacuum or inert atmosphere to avoid rapid oxidation of the die material.
 Advanced Forming Processes

Isothermal forging Process

 Advanced Forming Processes

High Energy Rate Forming (HERF)

• In these forming processes large amount of energy is applied for a very short interval of time
• Many metals tend to deform more readily under extra – fast application of load which make these processes
useful to form large size parts out of most metals including those which are otherwise difficult – to – form.
• Parts are formed at a rapid rate, and thus these processes are also called high – velocity forming processes.
• There are several advantages of using these forming processes,
 die costs are low,
 easy maintenance of tolerances,
 possibility of forming most metals,
 material does not show spring-back effect.
• Production cost of components by such processes is low.
• Limitation of these processes is the need for skilled personnel.
 Advanced Forming Processes

High Energy Rate Forming (HERF)

Types of high energy rate forming processes

• Explosive forming

• Magnetic forming

• Electro hydraulic forming

 Advanced Forming Processes

High Energy Rate Forming (HERF)

Explosive forming

• Explosive forming, is distinguished from conventional forming in that the punch or diaphragm is replaced by

an explosive charge.

• Explosives used are generally high – explosive chemicals, gaseous mixtures, or propellants.

• There are two techniques of high – explosive forming

 Stand – off technique

 Contact technique
 Advanced Forming Processes

High Energy Rate Forming (HERF)

Explosive forming: Stand – off technique

• Sheet metal work piece blank is clamped over a die and the assembly is lowered into a tank filled with water.

• Air in the die is pumped out.

• Explosive charge is placed at some predetermined distance from the work piece.

• On detonation of the explosive, a pressure pulse of very high intensity is produced.

• Gas bubble is also produced which expands spherically and then collapses.

• When the pressure pulse impinges against the work piece, the metal is deformed into the die with as high

velocity as 120 m/s.

 Advanced Forming Processes

Sequence of underwater explosive forming operations.(i) explosive charge is set in position (ii) pressure pulse
and gas bubble are formed as the detonation of charge occurs, (iii) workpiece is deformed, and (iv) gas bubbles
vent at the surface of water.