5 Common Types of Metal Forming Processes and Their Applications

Metal forming is an essential manufacturing process that manipulates metal material into desired shapes by applying force. It produces specific geometries needed for various end-use parts and products. Understanding the most common metal-forming techniques is key for both manufacturers and buyers of formed metal components.

In this article, we’ll review the definitions, workings, applications, advantages, and disadvantages of 5 common metal-forming processes. Let’s dive in!

1. METAL ROLLING

Rolling is a metal-forming process that presses metal stock between two opposing rotating cylinders to reduce thickness and create uniformity. The opposing rotational forces shape the workpiece to achieve the desired cross-section.

HOW ROLLING WORKS

During rolling, the metal strip gets squeezed between the rolls as it passes through, flattening, thinning, or lengthening it. This reduces the thickness while smoothing and cleaning the surface. The distance between rolls determines the amount of compression and deformation applied to the starting metal piece.

APPLICATIONS OF ROLLING

Common rolling applications include:

• Producing sheet metal
• Manufacturing plates, strips, and foils
• Forming structural steel sections like I-beams and railroad tracks
• Creating cylindrical sections like pipes, rods, wires

ADVANTAGES AND DISADVANTAGES

2. METAL EXTRUSION

Extrusion pushes heated metal through a die opening to create long pieces with a specific uniform cross-section. The die forms the workpiece to the desired shape as it exits.

HOW EXTRUSION WORKS

During extrusion, a hydraulic ram forces the soft metal alloy into the die cavity under high pressure. As the metal squeezes through the shaped opening, it stretches and hardens into that form. The continuous extrusion process can create bars, tubes, and specialty profiles in long lengths.

APPLICATIONS OF EXTRUSION

Typical extrusion applications:

• Aluminum window and door frames
• Pipes, tubes, and channels
• Rods and bar stocks
• Custom structural shapes

ADVANTAGES AND DISADVANTAGES

3. METAL FORGING

Forging uses localized compressive forces to mechanically form metal between design dies. Repeated impact deforms the raw material into high-strength finished parts.

HOW FORGING WORKS

In forging, the workpiece gets pressed between two dies that shift and shape the pliable metal when force is applied. The impressions from the dies form the desired geometry through a series of targeted high-pressure blows.

APPLICATIONS OF FORGING

Common forged parts include:

• Engine components
• Large bearings
• Cutting tools
• High-load transmission parts

ADVANTAGES AND DISADVANTAGES

4. METAL DRAWING

Drawing pulls sheet metal through a die to stretch it into various parts and assemblies with fine details. It produces lightweight components with dimensional accuracy.

HOW DRAWING WORKS

In drawing operations, the starting flat sheet gets gripped tightly and pulled through a shaping die cavity. This deepens the forms and compresses designated areas to make complex, drawn shell-like components.

APPLICATIONS OF DRAWING

Typical drawn parts include:

• Automotive bodies
• Aircraft fuselages
• Complex enclosures
• Culverts
• Medical equipment
• Tin cups

ADVANTAGES AND DISADVANTAGES

5. METAL STAMPING

Stamping presses sheet metal blanks between matched metalworking dies to mass-produce parts with custom geometries. It offers flexibility for both simple and complex components.

HOW STAMPING WORKS

The stamping press has a material-handling system to feed and locate sheet stock between the dies. It then presses the material to take shape through a series of cutting and forming steps during each stroke until achieving the final configuration.

APPLICATIONS OF STAMPING

Common stamping uses include:

• Vehicle panels
• Appliances
• Aircraft components
• Medical devices
• Electronics enclosures
• Flat shims

ADVANTAGES AND DISADVANTAGES

GET HIGH-QUALITY METAL MATERIAL FROM MEAD METALS

Understanding common metal forming techniques helps engineers select optimal manufacturing methods when designing parts. This leads to better quality, functionality, and efficiency.

At Mead Metals, we supply top-quality specialty metals to support your project needs. With value-added services like slit-to-length, slitting, and edge conditioning, we can facilitate metal-forming jobs from start to finish. Our Quick Quote turnaround is 4 hours or less, even for smaller order volumes that other suppliers won't accommodate.