Maulana Azad National Institute Of

Technology

Metallurgy and Material science engineering

Lab Report
Lab topic: Metal forming
Submitted by: Akash Tiwari
Sch No. 211119014
Submitted to: Dr. Ramkishor anant
Introduction:
Metal forming is a fundamental technique in manufacturing
used to shape metal pieces into desired configurations. It
involves applying force to plastically deform the metal, as
opposed to cutting or machining which removes material. This
process is akin to origami, but instead of folding paper, you are
bending and shaping metal.
There are several benefits to using metal forming:
Efficiency: Metal forming is a relatively waste-free process, as
minimal material is lost during shaping.
Accuracy: The formed parts can achieve high dimensional
accuracy. Versatility: A wide range of shapes, both simple and
complex, can be produced using different forming techniques.
Material Properties: The forming process can actually
improve the strength and grain structure of the metal
compared to casting.
Metal forming can be broadly categorized into two main
temperature conditions: hot working and cold working.
Hot Working: Here, the metal is heated to high temperatures,
making it more malleable and easier to shape. This process is
often used for creating large or complex shapes.
Cold Working: This method is performed at room temperature
or slightly above. Cold working results in a stronger final
product but requires more force to achieve the desired shape.
Here are some of the common metal forming processes:
Rolling: Sheets of metal are passed between rollers to reduce
thickness and achieve a desired uniform cross-section.
Forging: Metal is compressed using compressive forces to form
specific shapes. Forging is traditionally done with hammers and
anvils, but modern forging uses powerful presses.
Drawing: A sheet metal blank is pulled through a die to form a
new shape, often a cylindrical one like a cup or tube.
Extrusion: Metal is forced through a die opening to create a
long continuous profile with a specific cross-section. Think
toothpaste coming out of a tube.
Shearing: This is the process of cutting sheet metal using a
shearing force. While technically a forming process, it is used to
create blanks for other forming techniques or to cut parts to
size.
Content in lab/ Experiments performed in lab:
To perform cold forging operation on a steel sample and
determine the true strain.
To determine the true strain of mild steel and cobalt steel
sample after hot forging.
To perform hot forging operation on an aluminium sample and
to determine the true strain.
To study the change in microstructure feature after hot forging
of mild steel sample.
To study the change in microstructure after the hot forging of
cobalt steel sample.
To study the change in microstructure after the hot forging of
aluminium sample.
To study the changes in microstructure after the cold forging of
aluminium sample.

Description of Experiments performed in Lab:

01. To perform cold forging operation on a steel
sample and determine the true strain.
Cold forging is a metal forming technique performed at room
temperature or slightly above. It utilizes compressive forces to
shape a metal workpiece into a desired configuration. This
process strengthens the material through strain hardening but
requires higher forces compared to hot working. Determining
the true strain experienced by the metal during cold forging is
crucial for understanding its work hardening behavior and
predicting its final properties.
Objectives:
Perform a cold forging operation on a cylindrical steel sample.
Measure the initial and final dimensions of the deformed
sample. Calculate the true strain experienced by the sample.
Conclusion:
This experiment successfully demonstrated the cold forging
process and determined the true strain experienced by the
steel sample. The true strain value provides valuable
information about the degree of plastic deformation and the
potential work hardening effects on the material.
02. To determine the true strain of mild steel and cobalt
steel sample after hot forging.
Introduction:
Hot forging is a metal forming technique where the metal is
heated to a high temperature, making it more malleable and
easier to shape. This process allows for complex shapes to be
formed with lower forming forces compared to cold forging.
However, even at high temperatures, the metal still
experiences deformation and strain hardening. Determining
the true strain of the hot forged samples helps understand the
extent of deformation and predict their final properties.
Objectives:
Perform hot forging on cylindrical samples of mild steel and
cobalt steel. Measure the initial and final dimensions of the hot
forged samples. Calculate the true strain experienced by both
materials.
Conclusion:
This experiment successfully determined the true strain
experienced by both mild steel and cobalt steel samples after
hot forging. The true strain values offer insights into the plastic
deformation and potential work hardening effects for each
material.
 03. To perform hot forging operation on an
aluminium sample and to determine the true
strain.
Introduction:
Hot forging is a metal forming technique where the metal is
heated to a high temperature, making it more malleable and
easier to shape. This allows for complex shapes to be formed
with lower forces compared to cold forging. Aluminum, due to
its excellent workability at elevated temperatures, is a good
candidate for hot forging. This lab will guide you through
performing a hot forging operation on an aluminum sample and
determining the true strain it experiences.
Analysis:
Discuss the observed changes in the sample's dimensions after
hot forging. Relate the calculated true strain value to the
amount of deformation experienced by the sample.
Consider the limitations of hot forging measurements due to
high temperatures. How might these limitations affect the
accuracy of the true strain calculations?
04. To study the change in microstructure feature
after hot forging of mild steel sample
Introduction:
Hot forging is a metal forming technique where the metal is
heated to a high temperature, making it more malleable and
easier to shape. This process can significantly alter the
microstructure of the material, influencing its mechanical
properties. This lab explores how hot forging affects the
microstructure of a mild steel sample.
Analysis and conclusion:
Describe the observed microstructure features of the hot forged
mild steel sample.
Compare the microstructure of the hot forged sample with what
you expect for unformed mild steel (research typical
microstructure of mild steel).
Discuss how hot forging has affected the grain size and
distribution. Explain how the observed microstructure features
might influence the mechanical properties of the hot forged
steel.

05. To study the change in microstructure after the

hot forging of cobalt steel sample.
Introduction:
Hot forging is a metal forming technique used to shape cobalt
steel at elevated temperatures. This process alters the
microstructure of the material, influencing its mechanical
properties. This lab explores how hot forging affects the
microstructure of a cobalt steel sample.
Analysis and conclusion:
Describe the observed microstructure features of the hot forged
cobalt steel sample.
Compare the microstructure of the hot forged sample with what
you expect for unformed cobalt steel (research typical
microstructure of your specific cobalt steel alloy).
Discuss how hot forging has affected the grain size and
distribution. Explain how the observed microstructure features
(including the presence and morphology of secondary phases)
might influence the mechanical properties of the hot forged
cobalt steel.
06. To study the change in microstructure after the
hot forging of aluminium sample.
Introduction:
Aluminum is a popular choice for hot forging due to its excellent
workability at elevated temperatures. However, hot forging can
significantly alter its microstructure, influencing its mechanical
properties. This lab explores how hot forging affects the
microstructure of an aluminum sample.
Analysis and conclusion:
Describe the observed microstructure features of the hot forged
aluminum sample.
Compare the microstructure of the hot forged sample with what
you expect for unformed aluminum (research typical
microstructure of your specific aluminum alloy).
Discuss how hot forging has affected the grain size and
distribution.
Explain potential mechanisms like grain refinement or
recrystallization.
Explain how the observed microstructure features (including
the presence of second phases and dislocation density) might
influence the mechanical properties of the hot forged
aluminum.

07. To study the changes in microstructure after

the cold forging of aluminium sample.
Introduction:
Cold forging is a metal forming technique performed at room
temperature or slightly above. This process utilizes
compressive forces to shape aluminum, resulting in a work-
hardened material with a distinct microstructure compared to
its unformed state. This lab explores the impact of cold forging
on the microstructure of an aluminum sample.
Conclusion and analysis:
Describe the observed microstructure features of the cold
forged aluminum sample.
Compare the microstructure of the cold forged sample with
what you expect for unformed aluminum (research typical
microstructure of your specific aluminum alloy).
Discuss how cold forging has affected the dislocation density.
Explain how this high dislocation density relates to the work
hardening phenomenon in cold worked metals.
Analyze the observed deformation features and explain how
they indicate plastic deformation within the aluminum grains.
Consider the limitations of interpreting aluminum
microstructure, particularly the challenge of observing distinct
grain boundaries compared to other metals.
Microstructures obtained from above experiments are as
follows:
Final Conclusion:
In conclusion, this lab experiment provided valuable hands-on
experience with fundamental metal forming techniques. The
successful creation of the [name of metal object] demonstrates
the ability to [list the key skills learned, e.g., cut sheet metal to
precise dimensions, bend metal using a brake, assemble
components using fasteners]. Throughout the process, the
importance of [key takeaways, e.g., accurate measurement,
proper tool usage, following safety procedures] was reinforced.
Areas for improvement include e.g., achieving tighter bend
angles, minimizing material waste. This experiment provided a
solid foundation for understanding the principles and
applications of metal forming.