Forming

Forming• There are 4 main types of forming these are Press forming Embossing Deep drawing Spinning • Forming comes under processing metals in redistribution

• Redistribution – the process where materials are reshaped without loss of materials

Press Forming• This is usually carried out with the

materials at room temperature• Typically done in combination with

blanking in a stamping die. Press forming differs from bending because of more complex shapes and multi-axis forming on the various sheet steels.

• The process relies on the ductility of the material being pressed

• The materials used in this process are stainless steel, Aluminium, brass, cold rolled carbon steel, hot rolled carbon steel

• Examples are radiator panels, kitchen products – meat trays/cooker tops, car body panels

Advantages Disadvantage

A more 3D shape will greatly increased stiffness

If the material isn’t ductile it would snap or crack during the process

The materials structural strength increases

If it cracks it has to be thrown away and have to be started again

With the increase in stiffness when pressed means they can reduce the amount of necessary material

Tooling and production costs are expensive.

Embossing• This is similar to press forming. • The main difference is that

embossing is used to create decorative features with some quite intricate detail.

• materials used are aluminium, brass, cold rolled steel, copper, galvanized steel, high strength, low alloy, steel, hot rolled steel, steel and zinc

• Examples are jewellery, confectionary tins, appliance panels, building products, elevator panels, garage door panels, automotive trim and metal office furniture

Advantages Disadvantages

Create decorative features with some quite intricate detail

An expensive process unless it is being done on mass

Can be used on a lot of different materials when creating a design

No room for errors as it would be hard to rectify and this would be expensive

Can work on 3D shapes/objects

Deep Drawing• Deep Drawing is characterized by a considerable amount of slip between the

work material being formed and the active surface of the die. Forming operation in which a formed punch pushes against a flat sheet and forces it over a shaped die edge into the die cavity to take the shape of a recessed vessel. The outer edges of the sheet are normally restrained by a holder ring in order to prevent wrinkling of the side surfaces of the work piece.

• The materials used in this process usually are steel, aluminium, cooper, nickel• You can also use materials such as magnesium, titanium and zinc but it is

performed with great difficulty and wont always work.• Examples are soft drink cans (coke cola), automotive fuel tanks, kitchen sinks

Advantages Disadvantages

The ductility of the material allows material to be drawn out without fracturing

Tooling and production costs are expensive.

It is a quick process If it fractures it has to be scrapped and started again

It is a relatively expensive process

Spinning• This is a traditional process used

for forming 3D hollow objects from flat materials, it involves a circular sheet of material

• The materials used are aluminium, brass, copper, mild steel and stainless steel

• This process is usually done using a machine called mandrel, it’s similar to a lathe

• Examples are saucepans, woks, rocket nose cones, cookware, gas cylinders, brass instrument, bells and public waste receptacles

Advantages Disadvantages

Tooling and production costs are also comparatively low.

if a crack forms or the object is dented, it must be scrapped.

Spin forming is easily automated and an effective production method for prototypes as well as high production runs.

Conventional spinning also wastes a considerably smaller amount of material than other methods

Objects can be built using one piece of material to produce parts without seams. Without seams, a part can withstand higher internal or external pressure exerted on it. For example: scuba tanks, CO2 cartridges.

Other methods of forming round metal parts include hydro forming, stamping and forging or casting. Hydro forming and stamping generally have a higher fixed cost, but a lower variable cost than metal spinning.