PR3601 Metal Forming Technology Syllabus:
PR3601 Metal Forming Technology Syllabus – Anna University Regulation 2021
COURSE OBJECTIVES:
• Students will gain knowledge on the mechanism involved in plastic deformation and parameter representation.
• Students will read and understand the forging and rolling process and its recent technology.
• Students will read and understand the extrusion and drawing process and its recent technology.
• Student will have knowledge on various sheet metal forming process.
• Students will study the recent advancement and Special techniques in metal forming processes.
UNIT I FUNDAMENTALS OF METAL FORMING
State of stress – Components of stress, symmetry of stress tensor, principal stresses – Stress deviator – VonMises, 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 – Mannesmann 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.
TOTAL: 45 PERIODS
COURSE OUTCOMES:
Upon successful completion of the course, students should be able to:
CO1:Understand the fundamental mechanics of metal forming processes
CO2: Ability to understand the principle, classification, equipment used and applications of Rolling and Forging Processes
CO3: Ability to understand the principle, classification, equipment used and applications of Extrusion and Drawing Processes
CO4:Understand the principle, procedure of various sheet metal forming processes
CO5:Awareness about the recent advances in technology of metal forming.
TEXT BOOKS:
1. Dieter G.E., “Mechanical Metallurgy”, McGraw Hill, Co., Third Edition, 2017.
2. Nagpal G.R. “Metal forming processes”, Khanna publishers, New Delhi, 4thEdition, 2016.
REFERENCES:
1. SeropeKalpakjian, Steven R Schmid, “Manufacturing Process for Engineering Materials”, 6th Edition, Pearson Education, 2016.
2. Rao, P.N. “Manufacturing Technology”, Vol. 1, 5th Edition, Tata McGraw Hill Education (India) Private Limited, 2019.
3. Edward M.Mielink, “Metal working Science Engineering”, McGraw Hill, Inc, 2000.
4. Metal Handbook, “Forming and Forging”, Vol.14, Metal Park, Ohio, USA, 1990
5. Hosford W.F. and Caddell R.M. “Metal Forming: Mechanics and Metallurgy”, 4th Edition, Cambridge University press, Cambridge, 2011.