PR2302 METAL FORMING TECHNOLOGY
UNIT I FUNDAMENTALS OF METAL FORMING
State of stress – Components of stress, symmetry of stress tensor, principal stresses –
Stress deviator – von-mises, Tresca yield criteria – Octahedral shear stress and shear
strain theory – Flow stress determination – Temperature in metal forming – Hot, cold and
warm working – strain rate effects –metallurgical structures – residual stresses – Spring
back.
UNIT II FORGING AND ROLLING
Principle – classification – equipment – tooling – processes parameters and calculation
of forces during forging and rolling processes – Ring compression test - Post forming
heat treatment – defects (causes and remedies) – applications – Roll forming.
UNIT III EXTRUSION AND DRAWING PROCESSES
Classification of extrusion processes – tool, equipment and principle of these processes
– influence of friction – extrusion force calculation – defects (causes and remedies) –
Rod/Wire drawing – tool, equipment and principle of processes – defects – Tube
drawing and sinking processes – mannessmann process of seamless pipe
manufacturing – Tube bending.
UNIT IV SHEET METAL FORMING PROCESSES
Classification – conventional and HERF processes – presses – types and selection of
presses – formability studies – FLD, Limiting Draw ratio - processes: Deep drawing,
spinning, stretch forming, plate bending, Rubber pad forming, bulging and press brake
forming – Explosion forming, electro hydraulic forming, Magnetic pulse forming.
UNIT V RECENT ADVANCES
Super plastic forming – Electro forming – fine blanking – Hydro forming – Peen forming –
Laser Forming – Micro forming - P/M forging – Isothermal forging – high speed hot
forging – near net shape forming high velocity extrusion – CAD and CAM in forming
TEXT BOOKS
1. Dieter G.E., “Mechanical Metallurgy”, McGraw Hill, Co., S.I. Edition, 2001
2. Nagpal G.R. “Metal forming processes”, Khanna publishers, New Delhi, 2004
REFERENCES
1. Serope Kalpakjian, Steven R Schmid, “Manufacturing Process for Engineering Materials” – Pearson Education, 4th Edition, 2003.
2. Rao, P.N. “Manufacturing Technology”, TMH Ltd., 2003
3. Edward M.Mielink, “Metal working science Engineering, McGraw Hill, Inc, 2000.
4. Metal Hank book Vol.14, “Forming and Forging”, Metal Park, Ohio,USA, 1990
UNIT I FUNDAMENTALS OF METAL FORMING
State of stress – Components of stress, symmetry of stress tensor, principal stresses –
Stress deviator – von-mises, Tresca yield criteria – Octahedral shear stress and shear
strain theory – Flow stress determination – Temperature in metal forming – Hot, cold and
warm working – strain rate effects –metallurgical structures – residual stresses – Spring
back.
UNIT II FORGING AND ROLLING
Principle – classification – equipment – tooling – processes parameters and calculation
of forces during forging and rolling processes – Ring compression test - Post forming
heat treatment – defects (causes and remedies) – applications – Roll forming.
UNIT III EXTRUSION AND DRAWING PROCESSES
Classification of extrusion processes – tool, equipment and principle of these processes
– influence of friction – extrusion force calculation – defects (causes and remedies) –
Rod/Wire drawing – tool, equipment and principle of processes – defects – Tube
drawing and sinking processes – mannessmann process of seamless pipe
manufacturing – Tube bending.
UNIT IV SHEET METAL FORMING PROCESSES
Classification – conventional and HERF processes – presses – types and selection of
presses – formability studies – FLD, Limiting Draw ratio - processes: Deep drawing,
spinning, stretch forming, plate bending, Rubber pad forming, bulging and press brake
forming – Explosion forming, electro hydraulic forming, Magnetic pulse forming.
UNIT V RECENT ADVANCES
Super plastic forming – Electro forming – fine blanking – Hydro forming – Peen forming –
Laser Forming – Micro forming - P/M forging – Isothermal forging – high speed hot
forging – near net shape forming high velocity extrusion – CAD and CAM in forming
TEXT BOOKS
1. Dieter G.E., “Mechanical Metallurgy”, McGraw Hill, Co., S.I. Edition, 2001
2. Nagpal G.R. “Metal forming processes”, Khanna publishers, New Delhi, 2004
REFERENCES
1. Serope Kalpakjian, Steven R Schmid, “Manufacturing Process for Engineering Materials” – Pearson Education, 4th Edition, 2003.
2. Rao, P.N. “Manufacturing Technology”, TMH Ltd., 2003
3. Edward M.Mielink, “Metal working science Engineering, McGraw Hill, Inc, 2000.
4. Metal Hank book Vol.14, “Forming and Forging”, Metal Park, Ohio,USA, 1990
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