Forming Process

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By Rahmat Azis Nabawi

The forming process is a manufacturing operation in which a metal workpiece undergoes a controlled change in shape through the application of external forces. During this process, the workpiece experiences deformation, allowing it to assume a new geometry. Metal forming is one of the most important manufacturing processes because it enables the efficient production of components with high strength, dimensional accuracy, and good surface quality (Kalpakjian & Schmid, 2010).

Typical metal forming operations include rolling, bending, forging, extrusion, wire drawing, and deep drawing. These processes utilize specially designed tooling to apply forces to the workpiece while controlling the direction and magnitude of deformation. At the macroscopic level, deformation is generally classified into two types: elastic deformation and plastic deformation (Dieter & Bacon, 1986).

Elastic deformation is a temporary change in shape that exists only while an external force is applied. Once the load is removed, the material returns to its original dimensions. In contrast, plastic deformation is permanent. Even after the applied force is removed, the workpiece retains the new shape produced during the forming process (Dieter & Bacon, 1986).

Recent advances in sheet metal forming technology have enabled manufacturers to produce increasingly complex components with higher production rates and improved dimensional consistency. One significant development has been the application of hydraulic press systems in metal forming operations. Compared with conventional mechanical presses, hydraulic presses provide greater operational flexibility because both the applied pressure and ram stroke can be accurately controlled, resulting in better forming quality and process reliability (ASM International, 2006).

Metal forming processes may be classified according to several criteria, including working temperature, forming force, workpiece geometry, and manufacturing stage. Based on the working temperature, forming operations are divided into two major categories: hot working and cold working (Kalpakjian & Schmid, 2010).

According to DeGarmo, Black, and Kohser (2012), cold working processes can generally be classified into four major categories:

  • Squeezing (pressing)
  • Bending
  • Shearing
  • Drawing
Hydraulic Press Brake
Figure 1. Metal forming using a hydraulic press brake machine

References

  1. ASM International. (2006). ASM Handbook, Volume 14A: Metalworking—Bulk Forming. Materials Park, OH: ASM International.
  2. DeGarmo, E. P., Black, J. T., & Kohser, R. A. (2012). DeGarmo's Materials and Processes in Manufacturing (11th ed.). John Wiley & Sons.
  3. Dieter, G. E., & Bacon, D. J. (1986). Mechanical Metallurgy (3rd ed.). McGraw-Hill.
  4. Kalpakjian, S., & Schmid, S. R. (2010). Manufacturing Engineering and Technology (6th ed.). Pearson Education.

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