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Friction and Lubrication in Sustainable Metal Forming
Published in R. Ganesh Narayanan, Jay S. Gunasekera, Sustainable Material Forming and Joining, 2019
N. K. B. M. P. Nanayakkara, R. Ganesh Narayanan
It is well known that a lubricant is primarily used to overcome or to control friction between the tool and the workpiece. Some of the lubricants are specifically developed for metal forming instead of common applications in processes such as machining. The lubricants are available for the use in either at room temperature or at higher temperatures. However, in general, the lubricants have some common functions, and may vary considerably from one metal-working operation to another. The main function of lubricants used in metal forming is to control friction and tool wear (ASM Handbook, 2006). There are many supplementary requirements expected from forming lubricants: cooling material and tool (like billet and die in forging, roll and sheet in rolling, etc.) are among them. Furthermore, the lubricants support to produce good surface quality in formed parts without smudge, defects, etc. The residue film layers on metallic surfaces helps to minimize bacterial attack and oxidation before the succeeding operations, for example, the manufacturing deep drawn cans for food packaging and prevents the formed parts from corrosion and rust for extended storage. In certain situations, lubricants provide compatibility with lubricants in further operations, such as joining and surface coatings.
Introduction
Published in Xin Min Lai, Ming Wang Fu, Lin Fa Peng, Sheet Metal Meso- and Microforming and Their Industrial Applications, 2018
Xin Min Lai, Ming Wang Fu, Lin Fa Peng
Metal forming is an efficient manufacturing process for making net shape or near-net shape parts and components by employing the plasticity of materials to deform the materials. This traditional metal-forming process was a common practice for making simple tools a few thousand years ago. The blacksmith in ancient times used tools such as a hammer and an anvil to deform heated metals. Nowadays, this process offers many unique and attractive advantages, such as high productivity, low production cost, excellent material utilization, superior mechanical properties, and complex geometries of the deformed parts and components using the modern forming equipment [2]. With the ever-increasing costs of materials, energy, and manpower, and increasingly strict statutory regulations arising from environment-friendly and sustainable development, this conventional manufacturing technology is now facing more new challenges in terms of productivity, cost, and quality.
Metal Manufacturing and Finishing Waste Production and Utilization
Published in Sehliselo Ndlovu, Geoffrey S. Simate, Elias Matinde, Waste Production and Utilization in the Metal Extraction Industry, 2017
Sehliselo Ndlovu, Geoffrey S. Simate, Elias Matinde
The metal forming processes can be broadly categorized into (Kaushish, 2010) (1) direct compression type processes, such as forging and rolling; (2) indirect compression processes, such as deep drawing and extrusion and (3) bending processes. Essentially, the metal forming processes can further be subdivided into two main categories (Kaushish, 2010; Klocke, 2014): (1) hot forming, where the deformation is conducted above the recrystallization temperature but below the melting point of the metal and (2) cold forming, essentially carried out under ambient conditions or below the recrystallization temperature of the metal. Hot forming processes are most commonly applied for the primary solid state shaping processes such as forging, rolling, extruding, especially where larger reduction in the size without cracking of the specimen is required (Kaushish, 2010). In practice, cold forming would be more ideal over hot forming practices, mainly because (1) there are no energy costs for preheating the metal work piece, (2) there are no material losses due to scale formation and no finishing treatment process required to remove the oxide scales and (3) there are no dimensional faults due to shrinkage during the cooling of the hot-worked work piece (Klocke, 2014). However, the main disadvantages of cold forming processes include, inter alia, the requirement for higher force and limited formability of materials at ambient conditions. As a result, the hot forming processes are usually adopted industrially to specifically prevent the overload of forming machines and fracture of materials to be processed (Klocke, 2014).
Sheet metal shrink flanging process: a critical review of current scenario and future prospects
Published in Materials and Manufacturing Processes, 2023
Sheet metal forming is one of the major forms of forming technologies [1,2]. Sheet metal forming involves the deformation of sheet metal blanks with the help of die and tool sets by application of a variety of forces.[1,2] Sheet metal forming processes are influenced by the tool/workpiece material and geometry, working conditions, types of machineries as well as deformation mechanics of sheet metals.[1,2] Sheet metal forming majorly comprises deep drawing processes, conventional spinning, stretch forming, embossing, bending, explosive forming, electromagnetic forming and electro-hydraulic forming processes.[1,2] Products of sheet metal forming processes find their major applications in the manufacture of automobile parts, aircraft parts and home appliances. [3–6] In terms of industries, products of automobile stamping industry, aircraft industry, aerospace industry and home appliances industry and food packaging industry are found to be highly dependent upon sheet metal forming processes.[3–10]
Processing of DP590 steel using single point incremental forming for automotive applications
Published in Materials and Manufacturing Processes, 2021
Sandeep Pandre, Ayush Morchhale, Nitin Kotkunde, Suresh Kurra
Sheet metal forming process is extensively used for manufacturing complex shape lightweight components in the automotive, aerospace and biomedical fields.[4] Generally, a high capital investment needs to be done to make a dedicated punch and die setup for forming components of desired shape and size by a conventional stamping process. Before finalizing a product for the mass production, the demand of a fully tested complex shaped prototypes is increasing day by day from the customer end.[5–7] Thus, the usage of rapid prototyping techniques like the incremental sheet metal forming is rapidly increasing. The die-less nature, simple tooling, and formation of complex shaped prototypes with high cost-effectiveness made it a popular process across the manufacturing industries.[8]
Tribological and microstructural behaviour in coatings applied using GTAW and HVOF (thermal spraying process) and used to recover AISI/SAE D2 grade tool steels
Published in Welding International, 2018
Carlos Alberto Guevara Chávez, Jorge Leobardo Acevedo Dávila, Pedro Hernandez Gutierrez, Jose Jorge Ruiz Mondragon, Patricia del Carmen Zambrano-Robledo
The technological process of metal forming has a key feature which relates to the high cost of the tools that are used for the process itself. These are generally subjected to wear in their work zones, impact loads, hot working, tensile or compressive stresses on their structure due to the complex configurations of these tools and, therefore, non-uniformity in the distribution of the loads they are subjected to, among other aspects. The use of a repair weld is a viable option, since this process allows us to restore the part, with sufficient efficiency and low cost, with its original dimensional features and improved mechanical and tribological properties. Fe-Cr-Mo alloys are used in coatings for protecting components subjected to wear and corrosion [1]. High velocity oxygen fuels (HVOF) in Fe-Cr-Mo alloys have been reported to have provided good results in the field of spray coatings for tool steels for cold working.