Chapter 1-Introduction

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Tafila Technical University

Department of Mechanical Engineering


Manufacturing processes (2) / Metal forming processes
Dr. Ahmad Mostafa
1st semester 2021/2022
Manufacture: Is the term derived from two Latin words “Manus”, hand, and “Factus”, make. The
combination means “Made by Hand”.
Classes of materials in manufacturing:
1- Metals: Usually alloys, which are composed of two or more elements, at least, one of which
is metal.
2- Polymers: A compound formed of repeating structural unit called “mer”, whose atoms
share electrons to form very large molecules.
3- Ceramics: Molecules based on bonding between metallic and non-metallic elements, such
as oxides, nitrides, carbides. Usually used as insulators and refractories.
4- Sub-classes
a. Semiconductors
b. Composite materials
c. Bio materials
Basic groups of metals:
Figure 1 summarizes the basic groups of metals. Details and discussion are in the following section
to describe the figure contents.

Figure 1: Basic groups of metals


a. Ferrous metals: Based on iron and comprise of ~75% of metals production in the world.
Classifications of ferrous metals are:
1. Steels: iron-carbon alloy with 0.02 to 2.14 % C and other alloying elements such as
Mn, Cr, Ni, Mo, etc. Steels are classified as following:
i. Plain carbon steels
• Low carbon steel: Known as mild steel and contains less than 0.2 %C
• Medium carbon steel: Contains 0.2 to 0.5 %C and used for high strength
applications
• High carbon steel: Contains 0.5 to 2.14 %C and used for tools, blades
and springs
DR. AHMAD MOSTAFA MANUFACTURING PROCESSES (2) 1|CHAPTER 1
ii. Alloy steels: Alloying elements are added to improve the mechanical properties
of plain carbon steel.
• Low alloy steels: Contain less than 5 % alloying elements
• High alloy steels: Contain more than 5 % alloying elements
- Mn: improves strength and hardness
- Cr: improves strength and wear resistance
- Cu: improves strength and corrosion resistance
- Mo: improves heat resistance and toughness
- Ni: improves strength, toughness and corrosion resistance
- Si: improves strength and fluidity of liquid metal
iii. Stainless steels:
- Alloy steels designated to provide high corrosion resistance
along with high strength and ductility
- Contains Cr > 12%, which is the principal alloying element
- Ni, Mo, Ti, Mn are amongst other alloying elements
iv. Tool steels:
- High alloy steel designated for use as tools and dies in
machining and forming processes
- The toughness and wear resistance are balanced by various
combinations of W, Cr, Mo, Co, V, Si, Mn
- High speed steels (HSS), mold steels, hot-work tool steel and
cold work tool steel are examples of tool steels

Figure 2: Iron-Carbon partial binary phase diagram

DR. AHMAD MOSTAFA MANUFACTURING PROCESSES (2) 2|CHAPTER 1


2. Cast irons: Carbon is presented from 2.14 to 6.67%. Cast iron classified based on the
carbon form in the structure as:
i. Grey cast iron: Carbon presented as flakes and is used in the machine bodies.
ii. White cast iron: The term white came from the shiny surface after fracture.
Carbon presents as cementite and is used to build railways.
iii. Malleable cast iron: It is the heat treated white cast iron. The carbon remains in
clusters in the structure and is used for the pipe fittings.
iv. Ductile or nodular cast iron: It results by adding Mg to the grey cast iron. The
carbon presented as spheroids and used to cast complex geometries.

b. Nonferrous metals: All other metallic elements and their alloys, such as Al, Cu, Au, Mg,
Ni, Ag, Sn, Ti. Examples are:
- Brass: 65% Cu and 35% Zn
- Bronze: 90% Cu and 10% Sn
- Monel: Ni-Cu alloy
- AZ91: Mg-Al-Zn alloy

Factors influencing properties and manufacturing behavior of metals:


1- Atomic structure
2- Imperfections

Manufacturing processes:
Figure 3 summarizes the manufacturing processes. Details and discussion are in the following
section to describe the figure contents.

Figure 3: Classification of manufacturing processes

DR. AHMAD MOSTAFA MANUFACTURING PROCESSES (2) 3|CHAPTER 1


1- Solidification processes (Figure 4), in which the starting material is a heated liquid or
semifluid that cools and solidifies to form the part geometry
2- Particulate processing (Figure 5), in which the starting material is a powder, and the
powders are formed and heated into the desired geometry
3- Deformation processes, in which the starting material is a ductile solid (commonly metal)
that is deformed to shape the part
4- Material removal processes (Figure 6), in which the starting material is a solid (ductile or
brittle), from which material is removed so that the resulting part has the desired geometry.

Figure 4: Illustration of solidification process (1) pouring the fluid into a mold cavity and (2)
allowing the fluid to solidify, after which the solid part is removed from the mold.

Figure 5: Particulate processing: (1) the starting material is powder; the usual process consists of
(2) pressing and (3) sintering.

Figure 6: Common machining operations: (a) turning, in which a single-point cutting tool
removes metal from a rotating workpiece to reduce its diameter; (b) drilling, in which a rotating
drill bit is fed into the work to create a round hole; and (c) milling, in which a workpart is fed
past a rotating cutter with multiple edges.

DR. AHMAD MOSTAFA MANUFACTURING PROCESSES (2) 4|CHAPTER 1


Figure 7: Classification of metal forming operations.

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. Starting work shapes
for these processes include cylindrical billets and rectangular bars.

Figure 8: Basic bulk deformation processes: (a) rolling, (b) forging, (c) extrusion, and (d)
drawing. Relative motion in the operations is indicated by v; forces are indicated by F.

Rolling: It 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 so as to draw the work into
the gap between them and squeeze it.
Forging: 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.
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 own cross section.
Drawing: 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 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.

Figure 9: Basic sheet metalworking operations: (a) bending, (b) drawing, and (c) shearing: (1) as
punch first contacts sheet, and (2) after cutting. Force and relative motion in these operations are
indicated by F and v.
Bending involves straining of a metal sheet or plate to take an angle along a (usually) straight
axis.
Drawing is 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 9(b). To distinguish this operation from bar and wire drawing,
the terms cup drawing or deep drawing are often used.
Shearing. This process involves cutting the sheet metals rather than forming. A shearing
operation cuts the work using a punch and die, as in Figure 9(c). Although it is not a forming
process, it is included here because it is a necessary and very common operation in sheet
metalworking.

DR. AHMAD MOSTAFA MANUFACTURING PROCESSES (2) 6|CHAPTER 1

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