Fundamental concepts of metal forming technology nptel. It provides a detailed discussion of specific forming processes, such as deep drawing, rolling, bending extrusion and stamping. Important casting terms nptel course on manufacturing processes i, pradeep kumar et al. Apr 07, 20 nptel mechanical theory of machines 15 ebooks free download. For instance, toughness is an important but hardtodefine material property. The term plastic deformation describes permanent shape change, in contrast to elastic deformation. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. Topics include heat treatments, deformation, phasechange, and particulate consolidation processing of metals. Advanced metal forming processes details of high energy rate forming herf process electromagnetic forming, explosive forming electrohydraulic forming stretch forming 4.
Understanding basic principles of metal forming and further being applied by engineers and metallurgists directly contribute towards improvement in production in the industries. Manufacturing process ii fundamentals of metal forming 1. Electrohydraulic forming, also called electric discharge forming, is a unique high energy forming process for sheet metal. These are casting, machining, joining welding, mechanical fastners, epoxy, etc. Sheet metal forming processes mustansiriyah university. Sheet metal characteristics elongation the capability of the sheet metal to stretch without necking and failure. Metal forming processes mechanical engineering mcq questions and answers. Cold forming of sheet metal parts ernst grob ag youtube. Nptel provides elearning through online web and video courses various streams. Metal forming and machining processes springerlink. For each primary class of processes, such as forging, rolling, extrusion, wiredrawing, and sheetmetal forming, it explains how. Metal forming processes, also known as mechanical working processes, are primary shaping processes in which a mass of metal or alloy is subjected to mechanical forces. Various metal forming techniques and their analysis, viz. Mechanics of sheet metal forming college of engineering.
It enjoys industrial importance among various production operations due to its advantages such as cost. Sheet metal operations other sheet metal forming processes. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd analysis of cold rolling a more accurate method. Nptel mechanical engineering forming powder forming. Design for manufacturability sheet metal guidelines bends for the ease of manufacturing, multiple bends on the same plane should occur in the same direction. Avoid large sheet metal parts with small bent flanges.
Electromagnetic forming em forming or magneforming is a type of high velocity, cold forming process for electrically conductive metals, most commonly copper and aluminium. Property data given in this chapter are therefore given as ranges rather than as single values. Under the action of such forces, the shape and size of metal piece undergo a change. Sheet metal operations i lecture 38 sheet metal operations ii lecture 39 powder metallurgy forming i lecture 40 powder metallurgy forming ii. The surface areatovolume ratio of the starting metal is relatively high.
The characteristic is to use the mold cavity to apply high pressure to the molten metal. Nptel syllabus manufacturing processes i video course metal forming elastic and plastic deformation. Nptel mechanical theory of machines download on free books and manuals search nptel iits and iisc mechanical engineering. Cutting and forming thin sheets of metal usually performed as cold working sheet metal 0. Sheet metal forming involves forming and cutting operations performed on metal sheets, strips, and coils. Numerical methods are used increasingly to optimize product design and deal with problems in metal forging, rolling, and extrusion processes. This process is also known as electromagnetic forming. A first stage where the volume of the part is generated a second stage where the geometrical details are. Professor hosford is the author of more than 80 technical articles and numerous books, including the mechanics of crystals and textured polycrystals. Some of the original topics have been omitted or given in an abbreviated form in appendices. The course seeks to impart an understanding of those manufacturing methods traditionally not associated with a machine shop environment. The author highlights recent developments of metal forming technologies and explains sound, new and powerful expert system techniques for solving advanced engineering problems in metal forming. Spinning can be performed by hand or by a cnc lathe metal spinning does not involve removal of material, as in conventional wood or metal turning, but forming.
Metal spinning, also known as spin forming or spinning or metal turning most commonly, is a metalworking process by which a disc or tube of metal is rotated at high speed and formed into an axially symmetric part. Bulk metal forming, sheet metal forming stretching. Introduction to typical automotive sheet metal forming processes 1. Hot and cold working processes rolling, forging, extrusion, swaging, wire and tube drawing. Nptel mechanical engineering manufacturing processes i. Mse newsletter, sep dec 2019 volume 1 issue 3 mse department invites applications for faculty positions assistant professor, associate professor and professor level.
Deep drawing is a sheet metal forming process, while drawing is a bulk deformation process. The introduction of numerical methods, particularly finite element fe analysis, represents a significant advance in metal forming operations. Manufacturing processes i nptel online videos, courses. Analysis of the forming process, therefore is highly involved. Metal forming processes full notes ebook free download pdf. Since the shear stress gets reduced at higher temperatures, the hot working requires much less force to achieve the necessary. The concept of stress, deformation and failure, mechanics of metalworking and analysis of different metal. Maintaining precise material flow characteristics is crucial for producing a highquality stamped part.
Fundamentals of metal forming outline 9mechanical properties example 9overview of metal forming 9cold working strain hardening 9annealing recrystallization 9temperature in metal forming 9friction and lubrication in metal forming dr. The application of computeraided design and manufacturing techniques is becoming essential in modern metal forming technology. Stress required for forming, yield or flow stress therefore depends on several factors, such as strain, strain rate, temperature etc. Fundamental concepts of metal forming technologyquiz questions. Sheet metalworking bending operations deep or cup drawing shearing processes bulk deformation processes a forging b extrusion and c wire and bar drawing and d rolling. Using the finite element method in metalforming processes. In the rigidviscoplastic domain, the finite element method is being utilized as a forming process simulation tool, and in elastic and thermal domains, the method is being applied in forming tooling design.
Spinning can be performed by hand or by a cnc lathe. Download book pdf modeling of metal forming and machining processes pp 2 cite as. Starting with a brief survey of the early trends in metal extraction, the lectures will go on to present, within a logical, physicochemical framework, the fundamental. Nonferrous extractive metallurgy free materials science online course on nptel by iit kharagpur h. The course focuses on understanding the science and technology of different forming processes. Disadvantages of cold forming higher forces and power required surfaces of starting workpiece must be free of scale and dirt ductility and strain hardening limit the amount of forming that can be done in some operations, metal must be annealed to allow further deformation in other cases, metal is simply not ductile enough to be cold worked. Metal forming involves changing the shape of the material by permanent plastic deformation. Lecture series on manufacturing processes i by prof.
Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. Materials are subjected to complex states of stresses during forming. Thus process modeling for the determination of deformation mechanics has been a major concern in research. Metal forming processes indian institute of technology. Nptel mechanical engineering forming analysis of forming slab method r. Most of the metallic objects undergo at least one of the metal. Metal forming is a very important manufacturing operation. This manufacturing process uses the energy from the combustion of a thin metal. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of 9 plasticity 1. We wish you an enjoyable and informative learning experience. In recent years, finite element methods have been used extensively in the metal forming industry. L pugazhenthy the course will discuss the theoretical and practical aspects of extraction of nonferrous metals.
Combining forging forming with alternative production technologies can enable next generation products opportunities exist to break the economic barrier of tooling and provide flexible and configurable methods it is and can be high value manufacturing really achieving advances in metal forming requires a total route to market. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of 8 1. Chapter 4 metal matrix composites princeton university. Metal casting processes indian institute of technology. Building materials and construction 140602 engineering geology 140604. In recent years, enormous progress has been made in the analysis of forming of complex shapes using. An elastic deformation disappears when the load is removed. Manufacturing process ii fundamentals of metal forming 1 introduction metal forming includes a large group of manufacturing processes in which plastic deformation is used to change the shape of metal workpieces. Design for manufacturability sheet metal guidelines.
Mechanical engineering manufacturing processes i nptel. Mech521 manufacturing processes ii catalog description. Metal spinning does not involve removal of material, as in conventional wood. This article presents the technique of limit analysis, both upper and lower bound. Metal forming processes mechanical engineering mcq. There are four basic production processes for producing desired shape of a product. Nonferrous extractive metallurgy matsci 435 by nptel on. J s campbell, principles of manufacturing materials and processes. Forging process analysis and preform design by harshil parikh, bhavin mehta, jay gunasekera department of mechanical engineering ohio university, athens, ohio 45701 rob mayer, president queen city forging company, cincinnati, ohio 45226 abstract the purpose of this paper is to optimize the forging process and reduce the required force.
Strength of materials nptel online videos, courses iit. A first stage where the volume of the part is generated a second stage where the. After converting nonporous metal into product form by metal forming. Nasit 3 1 head of department, department of mechanical eng ineering, noble engineering college, junagadh, gu jarat. Study material from nptel civil engineering department. In light of these developments, the finite element methoda technique by which an object is decomposed into pieces and treated as isolated, interacting. Some mmc properties cannot be measured as they would be for monolithic metals. Lowcarbon steel is the most commonly used sheet metal because of its low cost and. Metal forming is the main method of making metal products and semifinished products. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses. Manufacturing technology, me202e d24 notes unit v metal forming process mohammad amir, lecturer, department of mechanical engineering, bhcet, dhauj, faridabad121004 page 3 3. Stresses beyond yield strength of the workpiece material is required. Civil engineering department civil engineering department. Nptel syllabus advanced manufacturing processes video course course outline.
Some of the heat may get dissipated through the surface. Thank you for signing up for our online course principles of metal forming technology. Metal forming analysis the introduction of numerical methods, particularly. Nptel mechanical engineering forming material behavior in metal forming r. Analysis and technology in metal forming 29 influence of strainrate i. More than 90% of smelted metal is processed by different methods of metal forming.
Nptel mechanical engineering forming joint initiative of iits and iisc funded. Including fem analysis describes metal forming theory and how experimental techniques can be used to study metal forming operations with great accuracy. When content is released on the portal, you will get an email alerting you. Analysis of forming slab method forming of materials is a complex process, involving either biaxial or triaxial state of stress on the material being formed. Medraj mech 4216511 lecture 32 example a metal obeys the hollomon relationship and has a uts of 300 mpa. Metal forming and the finiteelement method shiro kobayashi. Lecture 1 fundamentals of metal forming there are four basic production processes for producing desired shape of a product. Me 206 manufacturing processes 1 department academic. Carl zweben, metal matrix composites, contractor report for ota, january 1987. The term pressworking or press forming is used commonly in industry to describe general sheet forming operations, because they typically are performed on presses.
Metal forming is the final stage of metallurgical manufacturing permitting to produce metal ware used in national economy as the finished products or as the billet for further processing. Principles of metal forming technology announcements. Bulk deformation forging processes extrusion processes wire and bar drawing rolling processes 2. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page. Material deformation during sheet metal forming deformation analysis principal strain plane the analysis of deformation in sheet metal forming is often based on the two principal membrane strains. These methods have been useful in predicting forming loads, overall geometry changes of deforming workpieces, and qualitative modes of metal flow, and in determining approximate optimum process conditions. Mechanics modeling of sheet metal forming list of chapters preface 1.
Home category mechanical engineering mcq questions and answers metal forming processes. Metal forming is possible in case of such metals or alloys which are sufficiently malleable and ductile. This special issue on metal forming processes is dedicated to publishing highquality and original research in the field of manufacturing engineering. Hosford is a professor emeritus of materials science and engineering at the university of michigan. Under the action of such forces, the shape and size of metal. Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section. Two prominent methods of converting raw material into a product have been metal forming and machining. Plastic properties of metals are used during the process of metal forming.
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