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Bankura unnayani institute of

engineering

Submitted By:
Name : AKASH KARMAKAR
University-Roll: 10500724005
Class Roll No:06
Department: Mechanical Engineering
Semester: 3rd
Subject: Manufacturing Process
Topic : Technical report on “Forming Processes and
Their Defects”
Session: 2025-26
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INDEX
TOPIC PAGE NO

1. introduction 3-4

2. classification of forming processes 5-8

➢ Bulk Deformation Processes 5-6
➢ Sheet Metalworking 7-8

3. Application of forming 9

4. Conclusion 10
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INTRODUCTION
❖Definition of forming process
Forming is a category of manufacturing processes
that involves the deformation of a raw material into a
desired shape or form. These processes often involve the
application of external forces such as bending, stretching,
compressing, or twisting.
❖ Importance in mechanical/manufacturing industries
o Advantages for Industry
• High Productivity: Forming processes like forging,

rolling, extrusion.
• Material Efficiency: These methods typically generate

minimal scrap.
• Enhanced Mechanical Properties: Forming strengthens

products by refining their grain structure and improving

mechanical properties.
• Versatility and Complexity: The technology

accommodates a wide range of shapes, sizes, and

materials and enables .
o Applications in Manufacturing
• Production of Sheets, Rods, Plates, Beams, and Pipes:

Bulk forming and sheet forming processes fabricate

critical basic product forms required in numerous
industries.
• Automotive and Aerospace Components: Many key

structural and safety-critical parts are produced by

forming processes due to their strength and reliability.
• Cost Saving and Speed: Automation and process

advancements allow rapid production, cost-

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effectiveness, and flexibility to meet market demands

efficiently
❖ Difference between casting and forming
differences Casting Forming

Working Casting is a The plastic

Principle manufacturing deformation of a
process where a metal in order to
solid is melted, produce a useful
heated to proper shape. Metal
temperature forming is done at
(sometimes treated elevated
to modify its
chemical
composition), and is
then poured into a
cavity or mould,
Procedures 1.OBTAINING THE Metal-forming
CASTING GEOMETRY- processes:
2.PATTERNMARKING- 1. Drawing
3. COREMAKING 2. Extrusion
4. MOULDING 3. Forging
5. MELTING AND 4. Rolling
POURING
6. CLEANING
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Classification of Forming Processes

❖ Bulk Deformation Processes:
Bulk deformation processes are generally characterized by
significant deformations and massive shape changes, and
the surface area-to-volume of the work is relatively small.
The term bulk describes the work parts that have this low
area-to-volume ratio. Starting work shapes for these
processes include cylindrical billets and rectangular bars.
The figure illustrates different bulk deformation processes.
o Rolling :

This is a compressive deformation process in which the

thickness of a slab or plate is reduced by two opposing
cylindrical tools called rolls. The rolls rotate to draw the work
into the gap between them and squeeze it.

o Forging
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in forging, a workpiece is compressed between two opposing
dies, so that the die shapes are imparted to the work. Forging is
traditionally a hot working process, but many types of forging
are performed cold.

o Extrusion:

This is a compression process in which the work metal is forced

to flow through a die opening, thereby taking the shape of the
opening as its cross-section.

o Drawing:

o
In this forming process, the diameter of a round wire or
bar is reduced by pulling it through a die opening.
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❖ Sheet Metalworking:
Sheet Metalworking: Sheet metalworking processes are forming
and cutting operations performed on metal sheets, strips, and
coils. The surface-area-to-volume ratio of the starting metal is
high; thus, this ratio is a useful means to distinguish bulk
deformation from sheet metal processes. Press working is the
term often applied to sheet metal operations because the
machines used to perform these operations are presses. Apart
produced in a sheet metal operation is often called a stamping.
Sheet metal operations are usually accomplished using a set of
tools called a punch and die. The punch is the positive portion
and the die is the negative portion of the toolset.
types of forming sheet metal
The basic sheet metal operations are sketched in Figure and are
defined as follows:
o Bending:

Bending involves the straining of a metal sheet or plate to take

an angle along a (usually) straight axis.
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o Drawing:

In sheet metalworking, drawing refers to the forming of a flat

metal sheet into a hollow or concave shape, such as a cup, by
stretching the metal. A blank holder is used to hold down the
blank while the punch pushes into the sheet metal, as shown in
Figure. To distinguish this operation from bar and wire drawing,
the terms cup drawing or deep drawing are often used.
o Shearing:

This process seems somewhat out-of-place in a list of

deformation processes because it involves cutting rather than
forming. A shearing operation cuts the work using a punch and
die, as in Figure. Although it is not a forming process.
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Applications of Forming:
1. Automotive Manufacturing:
Metal forming is extensively used in the automotive
manufacturing industry. The majority of automobiles contain
sheet metal that has been shaped through various metal
forming processes.
2. Aerospace Engineering:
Applications within aerospace engineering include airplane
fuselages, wings, and engine components. While most parts
used in the construction of an airplane are made from either
metal or composite materials, metal is more often used in the
construction of fuselages and engine components because it
provides greater strength than composite material.
3. Construction:
Applications for metal forming processes within construction
include pipelines. Metal pipeline tubes are manufactured using
either hydraulic or electric resistance processes depending on
the desired shape. A new method called air-forming has
recently become popular because it allows for the production
of seamless pipes.
4. Press Working
Metal forming is a metalworking process that changes the
shape of metal using various application techniques, such as
squeezing, stamping, or bending. Applications of this type are
used broadly in the industry to fabricate and assemble parts
and products. Two processes: hot, can be used to form metal.
In hot forming, the metal is heated to a malleable state and
then shaped. Cold forming is performed without heating the
metal and uses force to deform it into the desired shape. The
two most common applications of metal forming are press
working and bending.
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Conclusion
Forming Process is a large set of the manufacturing process by
which raw material is converted into a product. In this process,
we apply stresses like tension, compression, shear, etc. Forming
Process is used to make many types of products in various
industries because it has various advantages over other
manufacturing processes. However, the Forming Processes also
have some drawbacks which should be taken into account
before choosing this process.