Forming Technology

Bulk Forming

Introduction to the Technology of Metal Forming

15/16 1.2L01 Introduction

Structure

1 Introduction to the technology of metal forming1.1 Introduction1.2 Classification of forming procedures1.3 Techno-economic aspects

15/16 1.3L01 Introduction

Classification of Manufacturing Procedures according to DIN 8580

Createform

Maintainform

Reduce form Increase form

Form alteration

6.Change of material properties

5.Coating

1.Moulding

2.Forming

3.Cutting

4.Joining

Displacementof materialparticles

Eliminationof materialparticles

Introductionof materialparticles

15/16 1.4L01 Introduction

Manufacturing Possibilities of a Bolt

Finished part

Small initialcross-section

Large initialcross-section(material is pressedthrough a nozzle)

Wastematerial

1. By casting( moulding )

2. Partial upsetting or extrusion (forming)

3. By turning( cutting )

4. By welding ( joining )

15/16 1.5L01 Introduction

Structure

1 Introduction to the technology of metal forming1.1 Introduction1.2 Classification of forming procedures1.3 Techno-economic aspects

15/16 1.6L01 Introduction

Classification of Forming Procedures into Subgroups according to DIN 8582

Forming

Rol

ling

Free

form

ing

Die

form

ing

Inde

ntat

ion

Extru

sion

Dra

win

g

Dee

p dr

awin

g

Flan

ge fo

rmin

g

Met

al s

pinn

ing

Ups

et b

ulgi

ng

Elon

gatio

n

Expa

ndin

g

Stre

tch

iden

ting

Bend

ing

with

stra

ight

tool

mot

ion

Bend

ing

with

rota

ryto

ol m

otio

n

Compressiveforming

Tensile-compressive

forming

Tensileforming

Bendforming

Shearforming

Shea

r for

min

g w

ith

stra

ight

tool

mot

ion

Twis

ting

15/16 1.7L01 Introduction

Compressive Forming: Impression Die Forging

Initial state Instant state Final state

F

Upper die

Blank

Lower die

Workpiece

15/16 1.8L01 Introduction

Tensile-Compressive Forming: Deep Drawing in the First Draw with Blank Holder

Initial state Instant state Final state

Punch

Blank holder

Blank

Die

F

FB FB

15/16 1.9L01 Introduction

Tensile Forming: Expanding with Rubber Punch

Initial state Instant state Final state

Punch

Rubber

Die

Workpiece

F

15/16 1.10L01 Introduction

Initial state Instant state Final state

Clamping jaw

Bending die

Tube

Bending role

F

Bend Forming: Tube Folding

15/16 1.11L01 Introduction

Initial state Instant state Final state

Shear Forming: Embossing of Sheet Metal Components

Punch

Blank holder

Sheet metal

Die

Counter punch

FP

FBH

15/16 1.12L01 Introduction

Dependence of the Maximum Formability on the Medium State of Stress

( according to H. Stenger )

Calibrating rolling

pilger rolling, form forging

Rolling with longitudinal tension

Drawing of wire and rods

Stretch-forming

Hollow section drawing

without mandrel

Hollow section drawing with mandrel

ironing

Band rolling with longitudinal

tension

Bandwalzen, Flachstabwalzen

Extrusion, bar extrusion, free forming (forging) on flat surfaces

Longitudinal rolling of blocks, upsetting

1 >2= 3

Uniaxialcompression test

Torsion test

Uniaxialtension test

-0.33 0 0.33m / k f

Br 1 >- 2 >- 3 m = 1

3 ( 1 + 2 3+ )1>2=3

Rolling of sheet metal

15/16 1.13L01 Introduction

Bulk forming

Upsetting ForgingBendingDeep drawing Extrusion

Sheet metal forming

Classification of Forming Procedures into Sheet Metal Forming and Bulk Forming

15/16 1.14L01 Introduction

Hot forming – Cold forming According to DIN 8582

Forming after heating - Hot forming

Forming without heating - Cold forming

Forming with permanent changein strength

Forming with temporary changein strength

Forming without change in strength

15/16 1.15L01 Introduction

Motion States During the Forming Process

Motion state of a transient formingprocess (upsetting)

StreamlineCourse line

Motion state of a stationary formingprocess (bar extrusion)

vWz

vWz

15/16 1.16L01 Introduction

Structure

1 Introduction to the technology of metal forming1.1 Introduction1.2 Classification of forming procedures1.3 Techno-economic aspects

15/16 1.17L01 Introduction

Material Savings by Cold Extrusion

Material: Ck 35

Quantity: 70 pieces/minuteMaterial savings: 75%(Hatebur)

15/16 1.18L01 Introduction

Comparison of Costs Forming - Turning

( According to K. Lange )

20 10

10 20

1020

Material coststurning

Material costsforming

10 16 25 40 63 100 160 3 250Lot size x 10 pieces

10

9

8

7

6

5

4

3

2

1

0

Prod

uctio

n co

sts

in €

/100

pie

ces

3

4

2

1

turned workpiece

3 single spindle turning automatic4 six spindle turning automatic

Material: 9 SMnPb 2 3

Formed workpieceMaterial: Ma 81 after forming2 machined after forming10 20

15/16 1.19L01 Introduction

Fibre of a Drive Shaft After the Extrusion

Material: 41 Cr 4Krupp

15/16 1.20L01 Introduction

Fibre of Crankshaft

Forged crankshaft

Crankshaft manufactured by„machining“

15/16 1.21L01 Introduction

Working Accuracy of Different Manufacturing Procedures After K. Lange

Achieveable working accuracy (diameter tolerance)ISO - quality

ProcedureDrop forgingExtrusionRolling (thickness)Sizing by rollingSizing (thickness)Deep drawingIroningTube and wire drawingCuttingPrecision cuttingSwagingTurningRound grinding

5 6 7 8 9 10 11 12 13 14 15 16

15/16 1.22L01 Introduction

Forming Technology and Lightweight Construction in Transportation Systems