Bulk & Sheet Forming Processes for Manufacturing Engineers

Study the fundamentals related to design and manufacturing of metallic products by Bulk and Sheet metal forming methods.

What you will learn

To become familiar with some of the basic metal forming processes like extrusion, rolling, forging, wire drawing and sheet metal working

Understand the fundamental concepts of different metal forming processes their engineering applications and limitations.

Apply their knowledge to select suitable process, variables, tooling and machines/equipment to make the products from various metal forming processes.

Determine the forces and power requirement in different metal forming processes.

Investigate defects appeared in the products manufactured by various metal forming processes and determine their causes and remedies.

Identification of metal forming parameters such as friction, temperature, the resistance of the material etc, necessary for defect free products.

Description

Forming Process also known as Metal Forming is a large set of manufacturing processes by which raw material is converted into a product. In this process, we apply stresses like tension, compression, shear, etc. to deformed the raw material. The example of forming processes are sheet metal manufacturing, forging, rolling, extrusion, wire drawing, and so on

Metal forming processes are an essential part of our society, and without them, our society would come to a grinding halt.

The products and components created by the different metal shaping techniques are used in creating everything from scaffolding and heavy machinery to designing and creating microprocessors and artificial intelligence.

When it comes to metal forming, there are several processes to choose from, with each offering its own list of benefits and detriments, each suited to certain applications, and each suited for different types of metal.

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

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

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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
Shearing
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 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

English

language

Content

Add-On Information:

Course Overview
- Delve into the foundational principles and advanced techniques of bulk and sheet metal forming processes, essential for the creation of robust and intricate metallic components.
- Explore the interdisciplinary nature of manufacturing engineering by integrating material science, mechanical design, and process optimization within the context of forming operations.
- Understand the transformation of raw materials into finished products through plastic deformation, emphasizing energy efficiency and material utilization.
- Gain insights into the selection of appropriate forming methods based on product complexity, material properties, production volume, and cost considerations.
- Analyze the influence of process parameters such as temperature, strain rate, tooling geometry, and lubrication on product quality, dimensional accuracy, and mechanical performance.
- Investigate the underlying physics of metal flow, fracture mechanics, and residual stress generation during various forming operations.
- Acquaint yourself with the design considerations for tooling, dies, and molds crucial for successful and repeatable manufacturing.
- Examine the integration of simulation tools and experimental validation for process design, troubleshooting, and performance prediction.
- Discuss the trends and future directions in bulk and sheet metal forming, including additive manufacturing integration and smart manufacturing technologies.
Requirements / Prerequisites
- A solid understanding of fundamental engineering mechanics, including statics and dynamics.
- Familiarity with basic material science principles, such as stress-strain relationships and material behavior under load.
- Proficiency in introductory calculus and differential equations.
- Prior exposure to manufacturing processes or an equivalent introductory engineering course is recommended.
- Access to a computer with relevant engineering software capabilities is beneficial for simulation and analysis.
Skills Covered / Tools Used
- Metal Forming Principles: Mastery of concepts like plasticity, yield criteria, strain hardening, and ductility.
- Process Analysis: Ability to analyze and predict outcomes of forging, extrusion, rolling, drawing, stamping, deep drawing, and bending operations.
- Tooling Design: Understanding of die and mold design principles, material selection for tooling, and wear mechanisms.
- Material Selection: Expertise in choosing appropriate metallic materials based on forming characteristics and end-use requirements.
- Simulation Software: Proficiency in using Finite Element Analysis (FEA) software (e.g., ANSYS, Abaqus, DEFORM) for process simulation and optimization.
- CAD/CAM Integration: Understanding how Computer-Aided Design and Computer-Aided Manufacturing principles apply to tooling and part design.
- Troubleshooting: Capability to identify and resolve common defects and issues encountered in forming processes.
- Data Analysis: Skills in interpreting simulation results and experimental data for process improvement.
Benefits / Outcomes
- Develop the expertise to design, analyze, and optimize bulk and sheet metal forming processes for various manufacturing applications.
- Enhance your ability to select the most suitable forming method for specific product requirements and production constraints.
- Gain a competitive edge in the manufacturing engineering field with specialized knowledge in a critical area of production.
- Improve product quality, reduce material waste, and increase manufacturing efficiency through informed process design.
- Contribute to the development of innovative and cost-effective metallic components for industries such as automotive, aerospace, medical devices, and consumer goods.
- Be equipped to lead projects involving the implementation and improvement of forming operations.
- Foster a deeper appreciation for the transformation of materials and the engineering challenges involved in mass production.
PROS
- Highly practical and directly applicable to industrial manufacturing challenges.
- Develops critical problem-solving skills for real-world production scenarios.
- Opens doors to diverse career opportunities in a wide range of industries.
- Provides a strong foundation for further specialization in advanced manufacturing.
CONS
- Can require significant theoretical understanding alongside practical application.