MF4203 Theory of Metal Forming Syllabus:

MF4203 Theory of Metal Forming Syllabus – Anna University PG Syllabus Regulation 2021

OBJECTIVES:

1) To study the basic concepts of metal forming techniques and to develop force calculation in metal forming process.
2) To study the thermo mechanical regimes and its requirements of metal forming
3) To learn the art of processing and making of powder metallurgy components
4) To learn the effect of friction and lubrication in Metal forming
5) To study the various surface treatment processes

UNIT I THEORY OF PLASTICITY

Theory of plastic deformation – Yield criteria – Tresca and Von-Mises – Distortion energy – Stress-strain relation – Mohr’s circle representation of a state of stress – cylindrical and spherical co-ordinate system – upper and lower bound solution methods – Overview of FEM applications in Metal Forming analysis.

UNIT II THEORY AND PRACTICE OF BULK FORMING PROCESSES

Analysis of plastic deformation in Forging, Rolling, Extrusion, rod/wire drawing and tube drawing – Effect of friction – calculation of forces, work done – Process parameters, equipment used – Defects – applications – Recent advances in Forging, Rolling, Extrusion and Drawing processes – Design consideration in forming – Equal Chanel Angular Pressing-High Pressure Torsion- Repetitive Corrugation and Straightening- Accumulative Roll bonding.

UNIT III SHEET METAL FORMING

Formability studies – Conventional processes – H E R F techniques – Superplastic forming techniques – Hydro forming – Stretch forming – Water hammer forming – Principles and process parameters – Advantages, Limitations and applications

UNIT IV POWDER METALLURGY AND SPECIAL FORMING PROCESSES

Overview of P/M technique – Advantages – applications – Powder preform forging – powder rolling – Tooling, process parameters and applications. – Orbital forging – Isothermal forging – Hot and cold isostatic pressing – High speed extrusion – Rubber pad forming – Fine blanking – LASER beam forming

UNIT V SURFACE TREATMENT AND METAL FORMING APPLICATIONS

Experiment techniques of evaluation of friction in metal forming selection – influence of temperature and gliding velocity – Friction heat generation – Friction between metallic layers – Lubrication carrier layer – Surface treatment for drawing, sheet metal forming, Extrusion, hot and cold forging.
Processing of thin Al tapes – Cladding of Al alloys – Duplex and triplex steel rolling – Thermo mechanical regimes of Ti and Al alloys during deformation – Formability of welded blank sheet – Laser structured steel sheet – Formability of laminated sheet.

OUTCOMES:

1) At the end of this course the students are expected to upgrade their knowledge on various metal forming techniques and formability
2) Apply the theory of plasticity for various types of metal forming process.
3) Apply the concept of powder metallurgy to make prismatic components
4) Understand Non-traditional forming processes.
5) Understand the purpose of surface treatment in metal forming applications.

REFERENCES:

1. Altan T., Metal forming – Fundamentals and applications – American Society of Metals, Metals park, 2003
2. ALTAN.T, SOO-IK-oh, GEGEL, HL – Metal forming, fundamentals and Applications, American Society of Metals, Metals Park, Ohio, 1995.
3. ASM Hand book, Forming and Forging, Ninth edition, Vol – 14, 2003
4. Dieter G.E., Mechanical Metallurgy (Revised Edition II) McGraw Hill Co., 1988
5. Helmi A Youssef, Hassan A. El-Hofy, Manufacturing Technology: Materials, Processes and Equipment, CRC publication press, 2012.
6. Marciniak,Z., Duncan J.L., Hu S.J., ‘Mechanics of Sheet Metal Forming’, Butterworth-Heinemann An Imprint of Elsevier, 2006
7. Nagpal G.R., Metal Forming Processes- Khanna publishers, 2005.
8. SAE Transactions, Journal of Materials and Manufacturing Section 5, 1993-2007
9. SHIRO KOBAYASHI, SOO-IK-oh-ALTAN, T, Metal forming and Finite Element Method, Oxford University Press, 2001.
10. Surender Kumar, Technology of Metal Forming Processes, Prentice Hall India Publishers, 2010