FORMING, WORKING and HEAT-TREATING METAL

This task arranged to complete the courses of English

Arranged by:

Refka Darmawan T

Gibran Juniansyah

Ilham Nurdiansyah

(2613161005)
(2613161011)
(2613161014)

MAGER OF METALLURGY ENGINEERING

FACULTY OF ENGINEER
UNIVERSITY OF JENDERAL ACHMAD YANI
BANDUNG
2016

METAL FORMING
A. Definition
Metal forming is the final stage of metallurgical manufacturing permitting to produce metal ware used in
national economy as the finished products or as the billet for further processing. Metal forming is the
main method of making metal products and semi-finished products. More than 90% of smelted metal is
processed by different methods of metal forming. Plastic properties of metals are used during the process
of metal forming. That is the ability to change without damage the shape and dimensions in hot and cold
condition under the pressure of machining tools. The knowledge of metal forming rules permits to realize
the forming at optimum deformation regimes and to use the appropriate main and auxiliary equipment.
The variety of methods and kinds of metal forming permits producing the wide range of metal products
with high productivity, exact dimensions, required mechanical properties. The development of
metallurgical manufacture has resulted in appearance of new kinds of metal forming where the processes
of casting and hardening metal reduction are being combined. New technological processes of metal
forming give the possibility to shape the product at high strain rate, to obtain the products with especially
high mechanical properties, to reduce the number of process stages and equipment used for it.
B. Types of Metal Forming

1. Rolling
Rolling is the most commonly used and the most efficient type of metal forming, which consists in
deformation of metal by means of rotating rolls (Fig. 1.1, a, b, c); 75-80% of the total quantity of smelted
metal is being processed by rolling.

d
Fig. 1.1. The schemes of the metal forming processes: a lengthwise rolling; b cross rolling; c helical
rolling (1, 2 rolls; 3 billet; 4 shell; 5 mandrel); d smith forging; e closed die forging; f
drawing; g pressing (extrusion); h sheet stamping
The long length products of constant or variable crosssection along the product length are produced by
method of lengthwise rolling. The direction of rolls rotation promotes pulling the billet by means of
friction forces to the gap between the rolls where the billet is reduced in thickness. It results in increase of
the length and the width of the billet. The rolls with smooth surface are used for rolling plates and roll
grooves forming the required shape of strip cross section passes are used for production of section
bars beams, channels, rails etc. During the process of cross rolling the rolls are rotating in the same
direction. The billet is fed in axial direction and it receives the rotational movement contacting the rolls.
The billet is retained in rolls by special device during the process of rolling and reducing by rolls. The
sections being the bodies of revolution such as balls, gears etc. are produced by cross rolling
2. The helical (skew) rolling
The helical (skew) rolling is realized in barrel-shaped rolls rotating in the same direction and installed
with some skewness of axes. The billet feed in axial direction receives the rotational movement and
simultaneously, due to the rolls skewness of axes, the translational movement ahead. During the process
of billet rolling its diameter is reduced, the core of the billet becomes. The mandrel installed towards the
billet movement direction allows to obtain the hollow product the shell from which the tube is produced
by means of the further processing.
3. Forging
Forging is a widely used method of metal forming. There is a free forging (Fig. 1.1, d) and closed die
forging (Fig. 1.1, e). During the process of free forging the reduction of the forging piece height is
realized between two parallel surfaces of hammer heads, and the flow of metal in the transverse direction
is not limited by the shape of the heads. The variety of the manufactured products shapes is achieved by
the reduction of the billet in different directions, using of auxiliary operations of bending, twisting,
drawing, piercing etc. The billet is placed to the cavity of one die part and under the action of another part
of the die the billet is filling the cavity taking its shape during the process of die forging. It makes the
process of the product shaping simpler and permits to increase the efficiency of forging.
4. The drawing of the metals

The drawing of the metals is used in manufacturing of small sections and relatively long length products
such as wire, rods, tubes (Fig. 1.1, f). The pointed end of the rod is pushed through the conical hole of the
tool (drawing die), is clamped at the die exit by clips or spooled and under the action of applied force is
drawn through the die with reduction of cross section area and corresponding elongation. The drawing
permits to obtain the products with exact dimensions and good quality of surface.
5. Pressing
Pressing is the method of product manufacturing by means of metal extrusion through the die hole (Fig.
1.1, g). It is mainly used in non-ferrous metallurgy and aviation industry where the shaped sections are
produced from such materials as Al- and Ti-based hard-to-deform and low-plasticity alloys.

6. Sheet stamping
Sheet stamping is the method of metal plastic processing in which the sheet and strip bars are used for
product manufacturing (Fig. 1.1, h). The complex shape products with high strength and rigidity and
small mass are produced in the process of separating, shaping and assembly operations; they are widely
used in many sectors of national economy. Sheet stamping is the highly efficient method of metal forming
and has the wide spreading.
C. Effect Of Temperature In Metal Forming
Properties of a metal change with an increase in temperature. Therefore, the metal will react differently to
the same manufacturing operation if it is performed under different temperatures and the manufactured
part may posses different properties. For these reasons, it is very important to understand the materials
that we use in our manufacturing process. This involves knowing their behavior at various temperature
ranges. In industrial metal forming manufacture, there are three basic temperature ranges at which the
metal can be formed, cold working, warm working, and hot working.
1. Cold Working
Cold working, (or cold forming), is a metal forming process that is carried out at room temperature or a
little above it. In cold working, plastic deformation of the work causes strain hardening as discussed
earlier. The yield point of a metal is also higher at the lower temperature range of cold forming. Hence,
the force required to shape a part is greater in cold working than for warm working or hot working. At
cold working temperatures, the ductility of a metal is limited, and only a certain amount of shape change
may be produced. Surface preparation is important in cold forming. Fracture of the material can be a
problem, limiting the amount of deformation possible. In fact, some metals will fracture from a small
amount of cold forming and must be hot formed. One main disadvantage of this type of process is a
decrease in the ductility of the part's material, but there are many advantages. The part will be stronger
and harder due to strain hardening. Cold forming causes directional grain orientation, which can be
controlled to produce desired directional strength properties. Also, work manufactured by cold forming
can be created with more accurate geometric tolerances and a better surface finish. Since low temperature
metal forming processes do not require the heating of the material, a large amount of energy can be saved
and faster production is possible. Despite the higher force requirements, the total amount of energy
expended is much lower in cold working than in hot working.

2. Warm Working
Warm working, (or warm forming), is a metal forming process carried out above the temperature range of
cold working, but below the recrystallization temperature of the metal. Warm working may be preferred
over cold forming because it will reduce the force required to perform the operation. Also, the amount of
annealing of the material that may have been necessary for the cold formed part may be less for warm
working.
3. Hot Working
Hot working, (or hot forming), is a metal forming process that is carried out at a temperature range that is
higher than the recrystallization temperature of the metal being formed. The behavior of the metal is
significantly altered, due to the fact that it is above its recrystallization temperature. Utilization of
different qualities of the metal at this temperature is the characteristic of hot working.
Although many of these qualities continue to increase with increasing temperature, there are limiting
factors that make overly high temperatures undesirable. During most metal forming processes the die is
often cold or slightly heated. However, the metal stock for hot working will usually be at a higher
temperature relative to the die. In the design of metal forming process, it is critical to consider the flow of
metal during the forming of the work. Specific metal flow, for different forming processes, is discussed in
latter sections under each specific process. For metal forming manufacturing, in general, the temperature
gradient between the die and the work has a large effect on metal flow during the process. The metal
nearer to the die surfaces will be cooler than the metal closer to the inside of the part, and cooler metal
does not flow as easily. High temperature gradients, within the work, will cause greater differences in
flow characteristics of different sections of the metal, these could be problematic. For example, metal
flowing significantly faster at the center of the work compared to cooler metal near the die surfaces that is
flowing slower, can cause part defects. Higher temperatures are harder to maintain throughout the metal
forming process. Work cooling during the process can also result in more metal flow variations. Another
consideration with hot forming manufacture, with regard to the temperature at which to form the part, is
that the higher the temperature the more reactive the metal is likely to be. Also if a part for a hot working
process is too hot then friction, caused during the process, may further increase heat to certain areas
causing melting, (not good), in localized sections of the work. In an industrial hot metal working
operation, the optimum temperature should be determined according to the material and the specific
manufacturing process.
When above its recrystallization temperature a metal has a reduced yield strength, also no strain
hardening will occur as the material is plastically deformed. Shaping a metal at the hot working
temperature range requires much less force and power than in cold working. Above its recrystallization
temperature, a metal also possesses far greater ductility than at its cold worked temperature. The much
greater ductility allows for massive shape changes that would not be possible in cold worked parts. The
ability to perform these massive shape changes is a very important characteristic of these high
temperature metal forming processes.
The work metal will recrystallize, after the process, as the part cools. In general, hot metal forming will
close up vacancies and porosity in the metal, break up inclusions and eliminate them by distributing their
material throughout the work piece, destroy old weaker cast grain structures and produce a wrought
isotropic grain structure in the part. These high temperature forming processes do not strain harden or
reduce the ductility of the formed material. Strain hardening of a part may or may not be wanted,

depending upon the application. Qualities of hot forming that are considered disadvantageous are poorer
surface finish, increased scale and oxides, decarburization, (steels), lower dimensional accuracy, and the
need to heat parts. The heating of parts reduces tool life, results in a lower productivity, and a higher
energy requirement than in cold working.

HEAT TREATING METAL

A. Definition
Heat treatment is a controlled process used to alter the microstructure of metals and alloys such as
steel and aluminium to impart properties which benefit the working life of a component, for example
increased surface hardness, temperature resistance, ductility and strength. heat treatment is not
necessarily as a process for hardening metal, as many heat treatments are applied to soften metal in order
to allow metal working operations such as deep drawing, cold forging and machining. There are five basic
heat treating processes: hardening, case hardening, annealing, normalizing, and tempering. Although each
of these processes bring about different results in metal, all of them involve three basic steps: heating,
soaking, and cooling. Heat treatment is the heating and cooling of metals to change their physical and
mechanical properties, without letting it change its Heat Treatment shape. Heat treatment could be said to
be a method for strengthening materials but could also be used to alter some mechanical properties such
as improving formability, machining, etc. The most common application is metallurgical but heat
treatment can also be used in manufacture of glass, aluminum, steel and many more materials. The
process of heat treatment involves the use of heating or cooling, usually to extreme temperatures to
achieve the wanted result. It is very important manufacturing processes that can not only help
manufacturing process but can also improve product, its performance, and its characteristics in many
ways.
Heat Treatment can also be said one of the processes to change the structure of the metal by heating the
specimen in the electric terance (furnace) at a temperature of recrystallization during a certain period of
time and then cooled in a cooling medium such as air, water, water Faram, oil and diesel fuel are
respectively each of which has a density varying cooling.
When the metal being subjected to heat their alloying elements affect the increase hardness and
strength of heat treatment results. Alloying elements which affect the hardness and strength of heat
treatment results are as follows:
1. Chromium
: its influence to increasing tension and violence, forms of violence and
stabilize carbides.
2. Phosphorous
: increasing the voltage and hardenability, reduced ductility and toughness.
3. Magnesite
: its influence to increase tension and violence, forming carbide, improve

hardenability, range of heat transfer

4. Silicon : effect on tense and tend to strengthen pearlite pearlite always to inflate
because of the element is used as the oxide magnesite.
5. Tungsten
: influence to shape and stabilize carbide hardness, increase range of
temperature and tempering temperature
6. Vanadium
: influence to strengthen the carbide forming element. Not used as a standalone element, but to combine carbide to austenite stainless steel.
7. Molybdenum
: strengthen carbide and forming element, and also improves high
temperature creep in style
B. Function
Some of the reasons for heat treating are:
1. To soften a part so that it can be machined more easily
2. To relieve internal stresses so that a part will maintain its dimensional stability (i.e., not warp
or fail prematurely due to lockedin stresses)
3. To refine the grain structure so that the part will be less apt to fracture abruptly (or to toughen)
4. To thoroughly harden a part so that it will be stronger 5. To case harden a part so that it will be
more wear resistant

C. TYPES
The heat treatment process there are two categories, namely:
Softening (Softening): Is an attempt to lose the mechanical properties to be soft by cooling the material
that has been heated in the furnace (annealing) or cool down in the open air (normalizing).
Hardening (hardening): Is an attempt to improve material properties, especially hardness by selup quickly
(quenching) material that has been heated to a quenching medium is water, salt water, and oil.

Hardening
Hardening involves heating of steel, keeping it at an appropriate temperature until all pearlite is
transformed into austenite, and then quenching it rapidly in water or oil. The temperature at which
austentizing rapidly takes place depends upon the carbon content in the steel used. For this process is
done with a heat input and heat transfer in a short time. The heating time should be increased ensuring
that the core will also be fully transformed into austenite. The microstructure of a hardened steel part is
ferrite, martensite, or cementite.
The purpose of hardening to alter the steel structure such that it obtained a hard martensitic
structure. The process is the steel is heated to a certain temperature between 770-830 C (depending on
carbon content) was then held at this temperature, a few moments later quenched by dipping in water, oil
or other cooling medium. With the sudden cooling, there is not enough time for the austenite to transform
into pearlite and ferrite or pearlite and cementite. Rapid cooling causes the austenite transformed to
martensite.

tempering
Tempering involves heating steel that has been quenched and hardened for an adequate period
of time so that the metal can be equilibrated. The hardness and strength Obtained depend upon the
temperature at the which tempering is Carried out. Higher Temperatures will result into high ductility, but
low strength and hardness. Tempering Low Temperatures will produce low ductility, but high strength and
hardness. In practice, tempering Appropriate Temperatures are selected that will produce the desired level
of hardness and strength. Used temperature between 100-400 degrees Celsius. This operation is
performed on all carbon steels that have been hardened, in order to reduce Reviews their brittleness, so
that they can be used Effectively in desired applications.
In the process of tempering the atoms will turn into a mixture of the phases ferrite and cementite
stable. Through tempering medium tensile strength will decrease ductility and toughness will be
increased. For quenching process after hardening is done suddenly, while after tempering is done with air
cooling. This cooling process would obviously result in the changing structure of metal diquench.
Tempering is divided into several sections, namely:
a. Tempering low temperature (150-300 C)
The goal is to reduce the voltage wrinkle and brittleness of steel. Used on a working tool that is not
experiencing heavy loads such as cutting tools and drill bits of glass.
b. Tempering medium temperature (300-500 C)
The goal is to add a little oomph and reduce violence. Used on a working tool Yanga suffered heavy loads
such as a hammer, chisel and spring.
c. Tempering high temperatures (500-650 C)
The goal is to provide great power tenacity and hardness will be lower. Used on gears, shafts, shaft drive.
annealing
The process of annealing or soften steel is prose steel heating above the temperature of critical
(723 C) then allowed some time until the temperature evenly, followed by cooling slowly while kept to
a temperature outside and inside is approximately equal to obtain the desired structure with using air
conditioners media.
Interest annealing process:
I. Soften metal material
II. Eliminate the stress / residual
III. Fixing metal grains.
Annealing involves treating steel up to a high temperature, and then cooling it very slowly to
room temperature, so that the resulting microstructure will possess high ductility and toughness, but low
hardness. Annealing is performed by heating a component to the appropriate temperature, soaking it at
that temperature, and then shutting off the furnace while the piece is in it. Steel is annealed before being
processed by cold forming, to reduce the requirements of load and energy, and to enable the metal to
undergo large strains without failure.

Normalizing
Normalizing Normalizing is a process of heating the metal until it reaches the desired austenite phase and

then gradually in the medium of air conditioning. This cooling results in the form of pearlite and ferrite
but the result is much smoother than annealing. The principle of the process of normalizing is to soften
the metal. But in high carbon steel or alloy steel limited to this process is not necessarily obtain soft steel.
May be hardening, and this depends on the carbon content.
Normalizing involves heating steel, and then keeping it at that temperature for a period of time, and then
cooling it in air. The resulting microstructure is a mixture of ferrite and cementite which has a higher
strength and hardness, but lower ductility. Normalizing is performed on structures and structural
components that will be subjected to machining, because it improves the machinability of carbon steels.
quenching
Quenching is a process that is done so that the steel is hot to cool. Quenching or hardening of steel is a
process of heating the metal so as to achieve a homogeneous austenite boundaries. To obtain homogeneity
is then audtenit takes adequate heating. Further quickly the steel is dipped into a cooling medium,
depending on the speed of cooling that we want to achieve hardness of the steel. At the time of rapid
cooling in the austenite phase does not have time to change into ferrite or pearlite because there is no
opportunity for the carbon atoms that have been dissolved in austenite to hold the movement of diffusion
and form cementite therefore occur phase last mertensit, this form of phase that is hard and depend on the
state of carbon. Media used in the quenching process is divided into two kinds, namely using liquid and
dry quenching. Examples which use liquid is water, oil, brine, caustic soda etc. As for the dry quenching
using air.
Working Metal
Traditionally, many metal tools were made by heating iron bars in a fire, called a forge, until they were
red hot or (hotter still) white hot. The metal was then worked in other words, shaped by hammering it.
Working metal using compression (for example, hammering) is also called forging. The same basic
technique is still in use today, espicially with steel. However, large, automated machines are now used.
Metal is often worked (or forged) when hot (hot forged), but may also be worked when itis cold (cold
forged).
A common forging technique is drop forging, where a heavy hammer is dropped onto a piece of metal. A
die fixed to the hammer compresses the metal into the required shape. Rollers can also be use to apply
compression, with or without heat, to produce hot rolled or cold rolled metal.
Forging also increases the hardness of metal. This is called work hardening. Metal becomes work
hardened because its structure is changed by compression. The same result can be achieved without
hammering or rolling and therefore without changing the componens shape by shot-peening. This
involves firing small metal balls (metal shot) at the surface of components (when cold), at high speed.
After component have been shot-peened, their surface is significantly harder.

REFERENCES
Cahyadi, Yusef (2011). Makalah Heat Treatment

Martins M, Castelleti L C. 2005, Effect of Heat Treatment on the Mechanical

Properties of ASTM A 890 Gr6A Super Duplex Stainless Steel. Journal of ASTM
International.

Martins M, Castelleti L C. 2004, Heat treatment temperature influence on ASTM

A890 GR 6A super duplex stainless steel microstructure. Journal of ASTM
International.

Budianto, Arief (2012). Heat Treatment. Dari

http://ariffbudianto.wordpress.com/2012/04/08/heat-treatment/, Diakses tanggal
12 April 2014