Deformation Processes

Deformation processes transform solid materials from one shape into another. It is a Process to make parts without material removal. The initial shape is usually simple (e.g., a billet or sheet blank) and is plastically deformed between tools, or dies, to obtain the desired final geometry and tolerances with required properties. A sequence of such processes is generally used to form material progressively from a simple geometry into a complex shape, whereby the tools represent the desired geometry and impart compressive or tensile stresses to the deforming material through the tool-material interface. Deformation processes are frequently used in conjunction with other unit operations, such as casting, machining, grinding, and heat treating, to complete the transformation from raw material to finished and assembly-ready discrete parts.

Classification and Characteristics of Processes

Deformation processes can be conveniently classified into bulk-forming processes (e.g., rolling, extrusion, and forging) and sheet-forming processes (e.g., stretching, flanging, drawing, and contouring). In both cases, the surfaces of the deforming material and of the tools are usually in contact, and friction between them has a major influence. In bulk forming, the input material is in billet, rod, or slab form, and a considerable increase in the surface-to-volume ratio occurs in the formed part. In sheet forming, a sheet blank is plastically deformed into a complex three-dimensional configuration, usually without any significant change in sheet thickness and surface characteristics.

Types of Deformation Processing

Rolling, forging, extrusion, wire-drawing, metal forming, tube reduction, HERF(high energy rate forming), superplastic forming, HIPping (high isostatic pressure) etc.

Rolling

Rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness and to make the thickness uniform

Forging

Forging is a manufacturing process involving the shaping of metal using localized compressive forces. The blows are delivered with a hammer (often a power hammer) or a die (a device for cutting or molding metal into a particular shape).

Extrusion

Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed through a die of the desired cross-section. It means that Manufacturing process in which a softened blank of a metal or plastic material is forced through a shaped metal piece or dies to produce a particular shape.

Wire drawing

Wire drawing is a metalworking process used to reduce the cross-section of a wire by pulling the wire through a single, or series of, drawing die or dies

Sheet Metalworking

Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking process. Thicknesses can vary significantly, although extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm are considered plate.

Forming Processes are:

Sheet Metalworking