MF7203 THEORY OF METAL FORMING

MF7203 THEORY OF METAL FORMING

UNIT I THEORY OF PLASTICITY

Theory of plastic deformation – Yield criteria – Tresca and Von-mises – Distortion energy – Stressstrain relation – Mohr’s circle representation of a state of stress – cylindrical and spherical co-ordinate system – upper and lower bound solution methods – Overview of FEM applications in Metal Forming analysis.

UNIT II THEORY AND PRACTICE OF BULK FORMING PROCESSES

Analysis of plastic deformation in Forging, Rolling, Extrusion, rod/wire drawing and tube drawing – Effect of friction – calculation of forces, work done – Process parameters, equipment used – Defects – applications – Recent advances in Forging, Rolling, Extrusion and Drawing processes – Design consideration in forming.

UNIT III SHEET METAL FORMING

Formability studies – Conventional processes – H E R F techniques – Superplastic forming techniques – Hydro forming – Stretch forming – Water hammer forming – Principles and process parameters – Advantage, Limitations and application 

UNIT IV POWDER METALLURGY AND SPECIAL FORMING PROCESSES 9

Overview of P/M technique – Advantages – applications – Powder preform forging – powder rolling –

Tooling, process parameters and applications. - Orbital forging – Isothermal forging – Hot and cold

isostatic pressing – High speed extrusion – Rubber pad forming – Fine blanking – LASER beam

forming

UNIT V SURFACE TREATMENT AND METAL FORMING APPLICATIONS

Experiment techniques of evaluation of friction in metal forming selection – influence of temperature and gliding velocity – Friction heat generation – Friction between metallic layers – Lubrication carrier layer – Surface treatment for drawing, sheet metal forming, Extrusion, hot and cold forging. Processing of thin Al tapes – Cladding of Al alloys – Duplex and triplex steel rolling – Thermo mechanical regimes of Ti and Al alloys during deformation – Formability of welded blank sheet – Laser structured steel sheet - Formability of laminated sheet.

REFERENCES:

1. Helmi A Youssef, Hassan A. El-Hofy, Manufacturing Technology: Materials, Processes and Equipment, CRC publication press, 2012.

2. SAE Transactions, Journal of Materials and Manufacturing Section 5, 1993-2007

3. Surender kumar, Technology of Metal Forming Processes, Prentice Hall India Publishers,2010

4. Marciniak,Z., Duncan J.L., Hu S.J., ‘Mechanics of Sheet Metal Forming’, Butterworth-Heinemann An Imprint of Elesevier, 2006

5. Nagpal G.R., Metal Forming Processes- Khanna publishers, 2005.

6. Altan T., Metal forming – Fundamentals and applications – American Society of Metals, Metals park, 2003

7. ASM Hand book, Forming and Forging, Ninth edition, Vol – 14, 2003

8. SHIRO KOBAYASHI, SOO-IK-oh-ALTAN, T,Metal forming and Finite Element Method, Oxford University Press, 2001.

9. Proc. Of National Seminar on “Advances in Metal Forming” MIT, March 2000

10. Dieter G.E., Mechanical Metallurgy (Revised Edition II) McGraw Hill Co., 1988

11. ALTAN.T, SOO-IK-oh, GEGEL, HL – Metal forming, fundamentals and Applications, American Society of Metals, Metals Park, Ohio, 1995.