Metal forming Processes (Mech 3-2)

Course Objective:

Metal forming processes are highly non linear because they involve geometric, material and contact non linearity. And so this subject introduce the concepts of one, two and three dimensional stress analysis, theory of plasticity, strain hardening, hot and cold working process. The students also will get the awareness on various types of rolling mills, forgings, extrusions, wire drawing processes, sheet metal operations, concepts on plastic manufacturing processes and rapid manufacturing process and its applications.

UNIT I

Stress, strain, Two dimensional stress analysis and three dimensional stress analysis, relation between engineering stress and true stress, relation between engineering strain and true strain, yield criteria, yield locus, theory of plasticity, Hot working, cold working, strain hardening, recovery, recrystallisation and grain growth, Comparison of properties of Cold and Hot worked parts

UNIT II

ROLLING: Bulk deformation processes – Economics of bulk forming, principles and theory of rolling, types of Rolling mills and products. Forces in rolling and power requirements, applications and, limitations, defects in rolled products – machinery and Equipment.

FORGING PROCESSES: Principles of forging –Types Forging – Smith forging, Drop Forging – Roll forging – Forging hammers: Rotary forging – forging defects, Forces in forging of strip, disc and power requirements, applications, Equipment and their selection.

UNIT III

EXTRUSION PROCESSES: Basic extrusion process and its characteristics. Mechanics of hot and cold extrusion - Forward extrusion and backward extrusion – Impact extrusion Hydrostatic extrusion, forces in extrusion of cylindrical and non cylindrical components – characteristics and defects in extruded parts. Wire Drawing: Process Mechanics and its characteristics, determination of degree of drawing, drawing force, power, and number of stages-defects in products.

UNIT IV

Sheet Metal Working – Economical Considerations - Stamping, forming and other cold working processes: Blanking and piercing – Bending and forming – Drawing and its types – Cup drawing and Tube drawing – coining – Hot and cold spinning. Force and power requirement in sheet metal operations, defects in sheet metal products – Equipment, tooling and their characteristics.

UNIT V

Processing of plastics, injection and blow moulding, calendaring, thermo forming, compression moulding, transfer moulding, High energy rate forming methods Rapid manufacturing: - Introduction – concepts of rapid manufacturing, information flow for rapid prototyping, classification of rapid prototyping process, sterer holography fused deposition modeling, selective laser sintering, Applications of rapid prototyping process

Study Material's for Metal Forming Processes

Lecture Notes(Complete): Download

Fundamental Concepts Of MFP: Download

Metal Forming Processes[PPT Format]: Download

2 Mark's for all Units: Download