Metal Forming Processes: The No-Nonsense OEM Guide
January 06, 2017
Metal forming processes reshape materials into usable components and products. Included here are the benefits and common applications of:
- Roll forming
- Extrusion
- Press braking
- Stamping
- Forging
- Casting
Check out this article for more detailed information on different metal forming processes.
1. Roll Forming
- Advanced inline addition of punched features and embossings
- Mid to large volumes
- Complex profiles with intricate bending
- Tight, repeatable tolerances
- Flexible dimensions
- Any length
- Little tool maintenance
- High tech
- Capable of forming high-strength metals
- Ownership of tooling
- Less room for error
- Less scrap - good for expensive materials
Common applications - construction, architecture
- Mounts
- Railings
- Framing
- Tubing
- Structural components
- Tracks
- Windows
- Door components
- Ladders
- Elevators
- HVAC
- Construction equipment
- Trains
- Ships
2. Extrusion
- Primarily aluminum but most metals can be extruded
- Punching or embossing done as a secondary operation
- Affordable dies (for aluminum)
- Hollow shapes without seam welding
- Complex cross-sections
- Various metals and alloys
Common applications - electronics, systems
- Tubing
- Aluminum cans
- Cylinders
- Injection tech
- Fuel supply lines
- Frames
- Tracks
- Rails
- Rods
- Bars
- Fittings
- Electrodes
- Structural components
3. Press Braking
- Low volumes, short runs
- Shorter length parts
- Compatible shapes with more simple bend patterns
- Higher labor content
- Less residual stress than roll forming
Common applications
- Sheet metal components
4. Stamping
- Single press stroke forming
- Consistent pieces with fixed dimensions
- Shorter length parts
- Higher volumes
- Complex parts in short amount of time
- High tonnage presses needed
- Value-added operations
Common component applications
- Gears
- Engines
- Aircraft components
- Electronics
- Telecom products
- Hardware
- Power tools
- Appliances
- Lock hardware
- Lawn care
- Ammunitions
- Lighting
5. Forging
- Precision forging combines production and manufacturing by forming the raw material into the desired shape, with the lowest possible amount of secondary operations needed
- Little to no subsequent fabrications
- Very high tonnage presses used
- Tougher end product
- High strength and hardness
Common applications - auto, aerospace
- Gears
- Steering arms
- Kingpins
- Axle beams
- Shafts
- Flanges
- Valves
- Drill bits
- Sockets
- Hooks
- Ball joints
- Missiles
- Landing gear
- Couplings
6. Casting
- A molding process
- Large range of alloys, custom alloys
- Affordable short run tooling
- Potential porosity
- Smaller runs
- Complex parts
Common applications
- Prototyping
- Heavy equipment
- Appliances
- Motors
- Artillery
- Art items
- Casings, covers
- Diffusers
- Valves
- Camera bodies
- Wheels
- Tooling
Again, for more detailed information, go to this article: Roll Forming vs. Press Braking & Other Metal Forming Methods
Topics: OEM Roll Forming, Metal Fabrication, Metal Forming, Processes, Roll Forming
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