Bulk & Sheet Forming Processes for Manufacturing Engineers
The course on Metal Forming Processes is a highly valuable educational opportunity for students and professionals interested in the manufacturing industry. Metal forming processes play a critical role in the production of various products, ranging from automotive and aerospace components to household appliances. Therefore, gaining an in-depth understanding of the principles involved in shaping metals through plastic deformation is a must for individuals looking to enhance their skill set in this field.
This course provides a comprehensive overview of the different types of deformation processes used in metal forming, including bulk deformation techniques such as rolling, forging, extrusion, and wire drawing, as well as sheet metal forming processes. Students will learn about the stress-strain curve, flow stress, and average flow stress, which are fundamental concepts that underpin the design and implementation of efficient manufacturing processes. Moreover, the course covers the analysis of various metal-forming operations and the equipment used in those processes.
In addition to the technical aspects of metal forming, the course also covers the defects that can occur during metal forming processes and their potential solutions. This knowledge is critical in designing and implementing manufacturing processes that meet the growing demand for precision products and cost-effective production methods.
Overall, the course on the Fundamentals of Metal Forming Processes is an excellent opportunity for individuals looking to pursue a career in the manufacturing industry or enhance their knowledge in this field. By enrolling in this course, students will acquire the skills and knowledge necessary to meet the increasing demand for precision manufacturing processes and become valuable assets in the industry.
Reference books for this course:
“Metal Forming: Mechanics and Metallurgy” by William F. Hosford and Robert M. Caddell
“Sheet Metal Forming Processes and Die Design” by Vukota Boljanovic and J. R. Nagy
COURSE OUTLINE
Introduction to the Fundamentals of Metal Forming Processes
Fundamentals of Metal forming
Types of deformation processes of metal
Bulk deformation (Rolling, Forging, Extrusion, Wire Drawing)
Sheet metal working
Stress-Strain Curve
Derivation of the relation between stress and strain
Flow stress and Average flow stress
The temperature in metal forming (Cold working and Hot-working)
Recrystallization
Iso thermal forming (recovery and Grain growth)
Strain rate Sensitivity
BULK-FORMING PROCESSES
Rolling Process
Introduction of rolling
Shapes used for rolling
Types of rolling
Working on the rolling process
Analysis of the rolling
Rolling mills
No-Slip Point for rolling
Flatness control and rolling defect
Numerical Problems related to the rolling process
Forging Process
Introduction to forging
Classification of forging
Types of forging
Analysis of the forging
Barreling effect in forging
Open Die forging and its practices
Impression Die forging and its practices
Advantages and Limitations of Impression Die forging
Fleshless forging
Forging Press and Forging Hammers
Numerical Problems Related to the forging process
Extrusion Process
Introduction to the extrusion process
Classification of extrusion
Direct and Indirect extrusion
Hot and Cold extrusion
Direct and Continuous extrusion
Analysis of the extrusion process
Effect of Friction on Extrusion
Extrusion Dies and Orifice
Extrusion press and other extrusion processes
Numerical Problems Related to the extrusion process
Drawing Process
Introduction to Drawing
Difference between drawing and wire drawing
Bar Drawing
Wire Drawing
Features of Draw Die
Preparation of the work
Analysis of the drawing process
SHEET METAL FORMING PROCESSES
Sheet metal Cutting
Introduction to sheet metal cutting process
Characteristics of Edges
Types of sheet metal cutting
Sharing
Blanking and Punching
Clearance in Sheet metal cutting
Analysis of sheet metal cutting processes
Numerical Problems Related to the sheet metal cutting process
Sheet Metal Bending
Introduction of sheet metal bending process
Types of sheet metal bending
Analysis of the sheet metal bending process
Numerical Problems Related to the sheet metal bending process
Spring Back
Sheet Metal Drawing
Introduction to the drawing process
Mechanics of drawing
Stages of deformation
Analysis of the drawing process
Tests of Drawing Feasibility
Blank force and blank size determination
Numerical Problems Related to the drawing process
Redrawing, Reverse Drawing, and Drawing without a Blank holder
Other drawing processes (Redrawing, Reverse Drawing, and Drawing without Blank holder)
Defects in Drawing
The operation performed with metal tooling
Ironing
Coining & Embossing
Lancing & Twisting
The operation performed with flexible Rubber tooling
Guerin and Hydroforming process
Numerical Problems related to the other drawing processes
Don’t miss out on the opportunity to expand your knowledge of metal-forming processes. Hurry up and enroll in this course.
Who this course is for:
All concepts are introduced slowly and gradually, but comfort with thinking analytically will be helpful.
Engineers in Mechanical, Manufacturing, Industrial, Electrical and other related fields looking for a way out of traditional processes for their projects and products.
Engineering students and professionals who want to level up their skills.
Anyone starting their career in the manufacturing and production world.