Outside the field of metal cutting, there are other metal working processes which entail no metal removal operation i.e. metal is deformed with no loss of volume. Some total of these processes which include both hot and cold working are called metal forming. Common metal forming operations include a) Hot forging- drawing down, upsetting, piercing, drifting, swaging. b) Closed die forging – drop stamp, drop hammer. c) Hot rolling d) Hot extrusion e) Cold rolling f) Tube drawing g) Wire drawing.
The requirement of the lubricant during forming operations is to lower the coefficient of friction between the blank work-piece and the die or tool. This effectively lowers the force required to carry out the forming operation which in turn reduces the power consumption and the generation of heat.
The lubricant also improves the process of deformation (metal flow) by additive action on the surface of the blank, it prevents excessive thinning of the material by reducing the stress; improves the surface quality of the work-piece and promotes cleanliness and corrosion protection.
Use of metal forming lubricants
increases the lifetime of the tool or die and provides a film which covers both surfaces of work-piece and the tool throughout the operation
thereby prevents metal-to-metal contact
that could cause welding pick up and surface damage.