Skip to main content

Materials in Metal Forming

  • Reference work entry
  • First Online:
Handbook of Manufacturing Engineering and Technology

Abstract

In this chapter, a review of the materials involved in the metal-forming processes and some of the processing required before forming on the materials are provided. At first the details of the materials formability definition and applications in different forming processes are discussed. Formability is one of the most important characteristics of the engineering alloys. Subsequently, information on the materials used for metal-forming tools and dies and their selection criteria are provided. These tool and die materials are categorized based on the process details and their limitation is further discussed. A brief look at the lubricants used in metal forming covers a subsequent topic in the current work and focuses on the effectiveness, characterization (friction reduction), types, and general applications as well as additives used in the lubricants. Lastly, a concise summary of the raw material preparation for forming processes is covered, with main focus on casting and heat treatment. These are the main preprocessing routes for preparing the preform in the industry. This chapter serves as a quick reference of forming process material selection for researchers, engineers, and students in the mechanical and materials engineering field.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 1,499.99
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Hardcover Book
USD 549.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Similar content being viewed by others

References

  • Ammen CW (2000) Metalcasting. McGraw-Hill, New York

    Google Scholar 

  • Aretz H (2004) Numerical restrictions of the modified maximum force criterion for prediction of forming limits in sheet metal forming. Model Simul Mater Sci Eng 12:677–692

    Article  Google Scholar 

  • Arrieux R (1995) Determination and use of the forming limit stress diagrams in sheet metal forming. J Mater Process Technol 53:47–56

    Article  Google Scholar 

  • Arrieux R, Bedrin C, Boivin M (1982) Determination of an intrinsic forming limit stress diagram for isotropic metal sheets. In: 12th biennial meeting of the international deep drawing research group, working group meetings, WG I, Santa Margherita Ligure, 24–28 May, pp 61–71

    Google Scholar 

  • Bai Y, Wierzbicki T (2008) Forming severity concept for predicting sheet necking under complex loading histories. Int J Mech Sci 50:1012–1022

    Article  MATH  Google Scholar 

  • Baker G, Wright R (1992) Drawing research with a high speed single die block. Wire J Int 25:71–73

    Google Scholar 

  • Bressan JD, Williams JA (1983) The use of a shear instability criterion to predict local necking in sheet metal deformation. Int J Mech Sci 25:55–168

    Article  Google Scholar 

  • Brunet M, Morestin F (2001) Experimental and analytical necking studies of anisotropic sheet-metals. J Mater Process Technol 112:214–226

    Article  Google Scholar 

  • Campbell J (2011) Complete casting handbook: metal casting processes, metallurgy, technology and design. Elsevier, Amsterdam

    Google Scholar 

  • Chow CL, Jie M (2004) Forming limits of Al 6022 sheets with material damage consideration theory and experimental validation. Int J Mech Sci 46:99–122

    Article  Google Scholar 

  • Chow CL, Yu LG (1997) Unified approach to metal fatigue based on the theory of damage mechanics. ASTM Spec Tech Publ 1315:165–185

    Google Scholar 

  • Chow CL, Yang XJ, Chu E (2002) Prediction of forming limit diagram based on damage coupled kinematic-isotropic hardening model under nonproportional loading transactions of the ASME. J Eng Mater Technol 124:259–265

    Article  Google Scholar 

  • Chow CL, Jie M, Hu SJ (2003) Forming limit analysis of sheet metals based on a generalized deformation theory, transactions of the ASME. J Eng Mater Technol 125:260–265

    Article  Google Scholar 

  • Cockroft MG, Latham DJ (1968) Ductility and the workability of metals. J Inst Metals 96:33–39

    Google Scholar 

  • Davis JR (1990) Properties and selection: irons, steels, and high-performance alloys, metals handbook, vol 1, 10th edn. ASM International, Materials Park

    Google Scholar 

  • Davis JR (1995) Tool materials, ASM Specialty handbook. ASM International, Materials Park

    Google Scholar 

  • Dossett JL, Boyer HE (2006) Practical heat treating. ASM International, Materials Park

    Google Scholar 

  • Fahrettin O, Lee D (2004) Analysis of forming limits using ductile fracture criteria. J Mater Process Technol 197:397–404

    Google Scholar 

  • Friedman PA, Pan J (2000) Effect of plastic anisotropic and yield criteria on prediction of forming limit curves. Int J Mech Sci 42:29–48

    Article  MATH  Google Scholar 

  • Ghosh AK, Laukonis JV (1976) The influence of strain path changes on the formability of sheet steel. In: 9th biennial congress of the IDDRG, sheet metal forming and energy conservation. ASM Publication

    Google Scholar 

  • Graf A, Hosford WF (1993) Calculations of forming limit diagrams for changing strain paths. Metall Mater Trans A 24:2497

    Article  Google Scholar 

  • Gurson AL (1977) Continuum theory of ductile rupture by void nucleation and growth: Part I. Yield criteria and flow rules for porous ductile media. ASME J Eng Mater Technol 99:2–15

    Article  Google Scholar 

  • Hagbart SA, Hopperstad OS, Tornqvist R, Amdahl J (2008) Analytical and numerical analysis of sheet metal instability using a stress based criterion. Int J Solids Struct 45:2042–2055

    Article  MATH  Google Scholar 

  • Hayward T Surface engineering of sheet metal forming dies. PhD thesis, University of Wollongong

    Google Scholar 

  • Hecker SS (1975) Simple technique for determining forming limit curves. Sh Metal Ind 52:671–675

    Google Scholar 

  • Hill R (1952) On discontinuous plastic states, with special reference to localized necking in thin sheets. J Mech Phys Solids 1:19–30

    Article  MathSciNet  Google Scholar 

  • Hora P, Tong L, Reissner L (1996) A prediction method for ductile sheet metal failure. In: Lee JK, Kinzel GL, Wagoner RH (eds) Proceedings of the NUMISHEET 1996 conference, Dearborn, pp 252–256

    Google Scholar 

  • Hutchinson JW, Neale KW (1978) Sheet necking – II. Time-independent behavior. In: Koistinen DP, Wang N-M (eds) Mechanics of sheet metal forming. Plenum Publishing Corporation, New York, pp 127–153

    Chapter  Google Scholar 

  • Kato K (1993) Active control of friction using tribo-coating in high-vacuum. J Jpn Soc Tribol 38:685–689

    Google Scholar 

  • Keeler SP, Backofen WA (1964) Plastic instability and fracture in sheets stretched over rigid punches. ASM Trans Quart 56:25–48

    Google Scholar 

  • Kuhn HA (1978) Formability topics – metallic materials, ASTM STP 647. ASTM International, Philadelphia

    Google Scholar 

  • Maclellan GDS (1952) Some friction effects in wire drawing. J Inst Metals 81:1–13

    Google Scholar 

  • Male AT, Cockroft MG (1964) A Method for the determination of coefficient of friction of metal under conditions of bulk plastic. J Inst Metals 93:38–46

    Google Scholar 

  • Marciniak Z, Kuckzynski K (1967) Limit strains in the process of stretch-forming sheet metal. Int J Mech Sci 9:609–662

    Article  Google Scholar 

  • Matin PH, Smith LM (2004) Practical limitations to the influence of through-thickness normal stress on sheet metal formability. Int J Plast 21:671–690

    Article  Google Scholar 

  • Mei Z, Morris JW (1993) Stress-concentration due to a hemispherical surface inclusion. Int J Fract 64:43–61

    Article  Google Scholar 

  • Ozturk F, Lee DY (2004) Analysis of forming limits using ductile fracture criteria. J Mater Process Technol 147:397–404

    Article  Google Scholar 

  • Ramana Rao TV (2003) Metal casting: principles and practice. New Age International (reprint), New Delhi, India

    Google Scholar 

  • Seah KHW, Lee KS (1988) The effects of titanium nitride coatings on punches and dies in the deep drawing of cold rolled mild steel. Int J Mach Tool Manuf 28:339–407

    Google Scholar 

  • Semiantin SL (1988) Forming and forging, metals handbook, vol 14, 9th edn. ASM International, Metals Park

    Google Scholar 

  • Simha CH, Grantab R, Worswick MJ (2007) Computational analysis of stress-based forming limit curves. Int J Solids Struct 44:8663–8684

    Article  MATH  Google Scholar 

  • Smith LM, Averill RC, Lucas JP, Stoughton TB, Martin PH (2003) Influence of transverse normal stress on sheet metal formability. Int J Plast 19:1567–1583

    Article  MATH  Google Scholar 

  • Storen S, Rice JR (1975) Localized necking in thin sheets. J Mech Phys Solids 23:421–441

    Article  Google Scholar 

  • Stoughton TB (2000) A general forming limit criterion for sheet metal forming. Int J Mech Sci 42:1–27

    Article  MATH  Google Scholar 

  • Stoughton TB (2001) Stress-based forming limits in sheet metal forming. J Engi Mater Sci 123:417–422

    Google Scholar 

  • Stoughton TB, Yoon JW (2004) A pressure-sensitive yield criterion under a non-associative flow rule for sheet metal forming. Int J Plast 20:705–731

    Article  MATH  Google Scholar 

  • Stoughton TB, Zhu X (2004) Review of theoretical models of the strain-based fld and their relevance to the stress-based FLD. Int J Plast 20:1463–1486

    Article  MATH  Google Scholar 

  • Swift HW (1952) Plastic instability under plane stress. J Mech Phys Solids 1:1–18

    Article  Google Scholar 

  • Ter Haar R (1996) Friction in sheet metal forming: the influence of local contact conditions and deformation. PhD thesis, University of Twente

    Google Scholar 

  • Totten GE (2007) Steel heat treatment: metallurgy and technology. Taylor & Francis, Boca Raton

    Google Scholar 

  • Wenzloff GJ, Van Tyne CJ, Matlock DK (1993) The importance of microstructure and properties on the formability of eletrogalvanized sheet steels. In: Marder AR (ed) The physical metallurgy of zinc coated steel. TMS, Warrendale, pp 275–293

    Google Scholar 

  • Wilson WRD, Hsu TC, Huang XB (1995) A realistic friction model for computer simulation of sheet metal forming processes. J Eng Ind 117:202–209

    Article  Google Scholar 

  • Wisterich JG (1955) Investigation of the mechanics of wire drawing. Proc Inst Mech Eng 169:654–665

    Article  Google Scholar 

  • Yao H, Cao J (2002) Prediction of forming limit curves using an anisotropic yield function with prestrain induced backstress. Int J Plast 18:1013–1038

    Article  MATH  Google Scholar 

  • Zhu X, Weinmann K, Chandra A (2001) A unified bifurcation analysis of sheet metal forming limits. J Eng Mater Technol Trans ASME 123:329–333

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Sridhar Idapalapati .

Editor information

Editors and Affiliations

Rights and permissions

Reprints and permissions

Copyright information

© 2015 Springer-Verlag London

About this entry

Cite this entry

Idapalapati, S. et al. (2015). Materials in Metal Forming. In: Nee, A. (eds) Handbook of Manufacturing Engineering and Technology. Springer, London. https://doi.org/10.1007/978-1-4471-4670-4_42

Download citation

Publish with us

Policies and ethics