Metalforming

Metalforming is a collective term for manufacturing processes that shape metal parts by plastic deformation rather than removing material. It includes bulk forming and sheet metal forming. The goal is to produce components with near-net shapes and desirable mechanical properties, with high production rates and good dimensional accuracy.

Bulk forming processes include forging (open-die, closed-die), extrusion, rolling, and drawing. In forging, metal is deformed between dies at elevated temperature or ambient; extrusion pushes material through a die to produce long shapes with constant cross-section; rolling reduces thickness or changes shape; drawing pulls metal through a die to reduce cross-section.

Sheet metal forming includes bending, stamping, deep drawing, ironing, hydroforming, and spinning. These processes transform sheet stock into complex geometries with relatively little material loss, often using progressive dies and high-tonnage presses. Temperature is typically ambient but hot forming is used for some alloys.

Key considerations include ductility, flow stress, friction, lubrication, and tooling design, which influence forces, wear, and part quality. Material selection (steel, aluminum, copper, titanium) and grain structure affect formability. Equipment ranges from mechanical, hydraulic, or servo presses to roller stands, extrusion presses, and dies.

Applications span automotive components, aerospace parts, consumer electronics housings, and industrial machinery. Advantages of metalforming include high-strength parts, good tolerances, and high material utilization. Limitations include high initial tooling costs, process design complexity, limitations with brittle materials, and the need for subsequent finishing operations in some cases.