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MY1302 METAL FORMING TECHNOLOGY
(Common to Metallurgy and Production)
1. STRESS TENSOR AND YIELD CRITERIA
State of stress, components of stress, symmetry of stress tensor, principal stresses, stress deviator, Von Mises, Tresca yield criteria, comparison of yield criteria, Octahedral shear stress and shear strain, Forming load calculations.
2. FUNDAMENTALS OF METAL FORMING
Classification of forming processes, Mechanics of metal working, Flow stress determination, Effect of temperature, strain rate and metallurgical structure on metal working, Friction and lubrication. Deformation zone geometry, Workability, Residual stresses.
3. FORGING AND ROLLING
Forging-types of presses and hammers. Classification. Open die forging and Closed die forging, die design, forging in plane strain, calculation of forging loads, forging defects- causes and remedies, residual stresses in forging. Rolling: Classification of rolling processes, types of rolling mills, hot and cold rolling, rolling of bars and shapes, forces and geometrical relationship in rolling, analysis of rolling load, torque and power, rolling mill control, rolling defects - causes and remedies.
4. EXTRUSION AND DRAWING
Direct and indirect extrusion, variables affecting extrusion, deformation pattern, equipments, Port-hole extrusion die, hydrostatic extrusion, defects and remedies, simple analysis of extrusion, tube extrusion and production of seamless pipe and tube. Drawing of rods, wires and tubes.
5. SHEET METAL FORMING AND OTHER PROCESSES
Forming methods - Shearing, blanking, bending, stretch forming, deep drawing. Types of dies used in press working, defects in formed part, sheet metal formability, formability limit diagram.
High velocity forming: Comparison with conventional forming. Explosive forming, Electro hydraulic, Electro Magnetic forming, Dynapak and Petro-forge forming.
TEXT BOOKS
1 Dieter.G.E ., “Mechanical Metallurgy”, McGraw-Hill Co., SI Edition, 1995.
2 Nagpal.G.R., “Metal Forming Processes”, Khanna Pub., New Delhi, 2000.
REFERENCES
1 Kurt Lange “Handbook of Metal Forming”, Society of Manufacturing Engineers. Michigan, USA, 1988
2 Avitzur, “Metal Forming - Processes and Analysis”, Tata McGraw-Hill Co., New Delhi, 1977.
3 ASM Metals Handbook. Vol.14, “Forming and Forging”, Metals Park, Ohio, USA, 1990.
4 Taylor Altan, Soo I.K. Oh, Harold.L.Gegel. “Metal Forming: Fundamentals and Applications”, ASM, Metals Park, Ohio, USA, 1983.
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