Forming technology
Forming technology is one of the key manufacturing technologies used in industrial production. It enables metallic materials to be shaped in a controlled manner without removing material. This produces components with high strength, optimised material distribution and efficient use of resources.
Forming in component production
Forming technology plays a particularly important role in sectors such as automotive manufacturing, electromobility and mechanical engineering. It provides the basis for producing complex components.
Forming encompasses a wide range of processes and applications. This article provides an overview of the fundamental principles and focuses on the forming processes and fields of application that play a central role in Felss’ industrial environment.
Definition of forming
Forming, or forming technology, is a manufacturing process in which materials are given a new shape through plastic deformation without removing any material. Unlike machining processes such as milling or turning, the material volume remains unchanged while the geometry of the workpiece is altered.
The role of forming technology in industrial manufacturing
Forming technology is an integral part of modern industrial production processes. It is used to manufacture components economically in large quantities while also modifying their mechanical properties in a controlled manner.
A major advantage of forming technology is that the material is not only shaped but also altered within its structure. This makes it possible to produce components that offer greater load-bearing capacity than comparable machined components with the same geometry.
Video: how components change during forming
Every forming operation affects the material structure: the required forces increase while formability decreases. Additional processes such as soft annealing, recrystallisation annealing or quenching and tempering are used to control this effect. They help prepare components optimally for subsequent forming operations and their intended application.
Forming technology at Felss
At Felss, we specialise in cold forming and support these processes throughout the entire value chain, from designing components suitable for forming and developing appropriate manufacturing processes to implementation in series production.
Our range of services includes both machine engineering and component manufacturing, allowing technological and production requirements to be closely integrated.
Forming processes
DIN 8582 classifies forming processes according to the mechanical stresses acting within the workpiece. This classification system provides a systematic structure for positioning forming technology within manufacturing processes.
The following main groups are distinguished:
- Compressive forming: DIN 8583-1 to DIN 8583-6
- Tensile-compressive forming: DIN 8584-1 to DIN 8584-6
- Tensile forming: DIN 8585-1 to DIN 8585-4
- Bending: DIN 8586
- Shear forming: DIN 8587
The following sections focus on compressive forming and bending, as these forming processes are particularly relevant to Felss.
Compressive forming
Compressive forming refers to forming processes in which a workpiece is plastically deformed primarily by compressive forces. The material is pressed into a die or between tools, causing its shape to change in a controlled manner.
Typical compressive forming processes include rolling and impact extrusion. They are used in particular to manufacture compact, highly load-bearing components that must meet strict requirements regarding dimensional accuracy, strength and material utilisation.
Compressive forming according to DIN 8583
According to DIN 8583, compressive forming can be divided into the following process groups:
- Rolling
- Open-die forming
- Closed-die forming
- Indentation
- Extrusion
This classification describes the different operating principles and tool concepts used in compressive forming.
Specialised processes such as axial forming and rotary swaging also belong to the category of compressive forming. These processes are among Felss’ core areas of expertise and enable controlled material flow as well as the production of complex, rotationally symmetrical components with optimised properties.
Bending
During bending, a workpiece is shaped by bending forces. The material is stretched on the outside of the bend and compressed on the inside.
The most important bending processes include tube bending, roll bending and profile bending. They are primarily used to manufacture components with defined angles or radii.
Classification of forming processes by temperature
Depending on the material properties and application requirements, forming processes are carried out at different temperatures. A decisive factor is whether the workpiece is heated above room temperature before or during forming, as this influences both the forming process and the resulting material properties.
On this basis, forming processes can generally be divided into two categories:
- Hot forming
- Cold forming
Cold forming processes
Cold forming refers to forming processes in which materials are plastically deformed below their recrystallisation temperature. The material volume remains unchanged while the geometry of the workpiece is altered in a controlled manner. At the same time, the material undergoes work hardening, which improves the mechanical properties of the components.
Examples of cold forming processes
Cold forming encompasses numerous processes based on established forming methods but carried out without additionally heating the material. Three examples of cold forming processes are presented below.
Cold rolling
Cold rolling refers to the rolling of materials in a cold state. Unlike hot rolling, the material is formed without being heated beforehand. In addition to changing the shape, the process also produces controlled work hardening and modifies the material structure.
Felss HMP Rolling technology delivers the highest levels of quality and reliability across all rolling processes.
The cold rolling process
During cold rolling, the workpiece is deformed between rotating rollers to modify its cross-section or improve its material properties in a controlled manner. The process is used particularly when strict requirements apply to dimensional accuracy, surface quality and mechanical properties.
Cold impact extrusion
In cold impact extrusion, the material is pressed into a die under high pressure, also without being heated beforehand. The process belongs to the group of compressive forming processes and is used to produce complex component geometries precisely and with efficient material utilisation.
Forming the material in a cold state produces components with high dimensional accuracy, excellent surface quality and increased strength.
Rotary swaging
Rotary swaging is a cold forming process that also belongs to the compressive forming processes defined in DIN 8583-3. It enables lightweight components to be produced efficiently and economically.
Rotary swaging explained briefly
During rotary swaging, several tools strike the workpiece in rapid succession and deform it incrementally. The material begins to flow and continuously adapts to the required geometry. Forming the material in a cold state also results in work hardening.
The process belongs to the category of incremental forming, in which the final shape is not produced in a single operation but through numerous consecutive, small forming steps. This enables the material flow to be controlled and the component geometry to be adjusted precisely.
