Squeezing and Forming
Squeezing and forming is the process of pressing and holding a workpiece in a die or a series of dies to deform it into a desired shape. This location and force combination along with heat and lubricating agents must be carefully managed to ensure uniform shape and size of the parts being formed. Squeezing and forming is a very common manufacturing operation used in any industry, and there are two main types of processes available: cold and hot forming.
Cold squeezing and forming is the process of applying pressure to a cold, or partially hardened, material without additional heat or lubrication. In this process, the workpiece is inserted into a die and force is applied to the workpiece to deform it into the desired shape. This type of cold forming is typically used for operations such as heading, threading, and various other shaping operations.
Hot squeezing and forming is the process of applying heat, pressure, and/or lubrication to cold, partially hardened, or fully hardened material to form components for a variety of applications. In a hot forming operation, the workpiece is heated to a specific temperature in order to increase malleability and decrease internal stresses. Once the material is softer and more malleable, it is then placed into a die and force is applied to the workpiece to deform it into the desired shape. Hot forming is typically used for operations such as drawing and rolling and is beneficial for high-volume production of complicated shapes.
The plastic deformation of workpieces to achieve the desired shape and size is a beneficial manufacturing operation due to its versatility and cost savings opportunities. This process is used to form a variety of metals in a cost-effective manner. Special lubricants, which are made of molecules that are engineered to a maximum tolerance, are used in some squeezing and forming operations and advanced machining centers may also be used to lower cost.
The advantages of squeezing and forming processes include:
- High productivity as workpieces may be rapidly produced from cold or hot materials
- Lower manufacturing costs due to low setup costs and improved utilization of material
- Achieving complex, three-dimensional and intricate shapes not otherwise possible
- Possibility of creating different material grades or properties
- Lower energy consumption and less environmental impact
On the other hand, disadvantages include:
- Geometrical constraints may limit design of components
- High dimensional accuracy is generally difficult to achieve
- Quality assurance is often challenging and requires specific expertise
In conclusion, squeezing and forming processes are economical and efficient solutions for producing parts with complex shapes and sizes with minimal setup costs and scrap material. Heat, pressure and lubrication must be carefully managed in each process in order to achieve the desired shape and size of the part.
