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:

1. “Metal Forming: Mechanics and Metallurgy” by William F. Hosford and Robert M. Caddell
2. “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.