A fabrication process called metal forming uses metal sheets or tubes to produce structural elements and components. A metal workpiece can be bent or deformed in a basic metal forming process to take on the appropriate geometric shape. Metal forming serves as a major industry unto itself and serves as the cornerstone of contemporary industrial manufacturing in a number of ways. Each year, hundreds of millions of tonnes of material are used in metal forming processes, which are thought to be responsible for 15% to 20% of the GDP of industrialized countries.

The manufacturing technique may create parts in large quantities for applications in the petrochemical, rail and marine, telecommunications, consumer and commercial electronics, agriculture, aerospace, automotive, durable goods, and appliance industries. All rely on parts that come from metal forming.

The Basics of Metal Forming

Metal forming, as a general word, refers to a variety of manufacturing procedures. All metal-forming techniques share one characteristic, however: the transformation of raw metal stock into a finished product.

The principle of plastic deformation, a mechanical procedure known in the material sciences, is used to reshape objects. By exerting a force greater than the material’s yield strength, plastic deformation of the material results. The physical shape of the material will change after the force is applied, and this change cannot be reversed.

Metal can be permanently bent, stretched, or compressed into another geometric shape through a process known as plastic deformation. The amount of stress placed on the metal determines how much it changes shape. The metal workpiece must reach its proportional stress limit before it may permanently change its shape. Metal is formed in order to accomplish this.

What Are the Metal Forming Processes?

During metal forming, metal must be put under a specified level of stress in order for it to go through plastic deformation, change geometrically into a fashioned component, or be used in part of industrial production. Any forming activity that causes the material to bend requires that it be exposed to tension, compression, or both. Not its bulk, but the metal’s shape is simply lost during the process.

Different kinds of metal forming methods are used for mass production in manufacturing industries. Among the most widely used methods are deep drawing, roll forming, stretching, and bending.

• Bending is a method for creating flexible metal that makes use of a brake press or other sort of press machine. By laying the metal sheet over a die block that punch-presses the material, the metal sheet is created. The die actually bends the metal sheet to suit the die, not really punching the sheet of metal.
• Another method of treating metal is stretching. To create intricate or large-scale contoured pieces, the workpiece is simultaneously stretched and bent over a die during the forming process. Radial strain is what causes the sheet to distort. The method is used to form massive components with smooth surfaces and sizable, precise radius bends.
• A typical method of producing metal is deep drawing. Using this method, hollow-shaped components are produced by clamping the metal sheet over a die having a cavity. It is forced into the cavity by the punch’s motion, which also forces it downward. With the application of tensile strength, the metal sheet is distorted and takes on the exterior shape of the portion.
• Metal is shaped throughout the roll forming process as it travels between various sets of rollers. Pairs of rollers constantly mold and bend the metal sheets or strips as they are fed through the machine, giving them the appropriate cross-sectional shape. The process is carried out iteratively, gradually shaping the piece to produce the desired cross-section. Typically, roll forming is used to create long components or large manufacturing runs.

Who Leads the Charge in the Metal Forming Industry?

The leading metal forming businesses and their most recent developments are listed below:

1. Voestalpine Metal Forming Division – The company’s area of expertise is the manufacture of excellent metal-formed assemblies and components for the transportation, railroad, aerospace, and energy industries. Voestalpine is attempting to develop metal components that can be 3D printed with characteristics that save weight and boost mechanical strength.
2. MetalForming LLC – MetalForming specializes in the fabrication and folding of sheet metal. The business has unveiled a new servo-electric press brake with enhanced processing capabilities and accuracy.
3. Beckwood Press Company – Beckwood Press manufactures specialized hydraulic and servo-electric presses, automation systems, and the Triform line of precise shaping tools. A new 200-ton forming press has helped the company increase the number of products it offers.

Final Thoughts

Science, creativity, and engineering come together in the fascinating field of metal forming. It is proof of human inventiveness and our unrelenting quest for excellence. Metal forming continues to have a profound impact on our society, from the ancient civilizations that first perfected the art to the cutting-edge technologies that shape it today.