Indicative contents

• Classification of forming process: Introduction to metal forming process, effect of temperature on forming process – Hot working and Cold working, effect of metallurgical structure, effect of speed of deformation, work of plastic deformation, friction in forming operation.
  
• Plasticity of metals: Tensile test-true stress-true strain-flow curves and their significance-strain rate-flow equations-principle stresses in 2D, Maximum shear stress-mohr circle representation-yield criteria-Tresca’s yielding criteria, Von-mises yielding criteria.
  
• Rolling: Introduction to rolling process-classification, determination of roll pressure, forces and relationships in rolling, variables in rolling, deformation in rolling, defects in rolling, residual stresses in rolled products, lubrication methods, torque and horsepower.
  
• Forging: Classification, forging of thin strip and flat circular discs in high friction and low friction condition. Forging equipment-brief description, deformation in compression, forging defects, residual stresses in forging.
  
• Extrusion: Classification, Extrusion equipment- forward, backward and side extrusion-hydrostatic extrusion, variables in extrusion, deformation pattern in extrusion, stress evaluation in extrusion, allowance for container friction, lubrication, and defects.
  
• Drawing of rods, wire & tubes: Wire drawing process, drawing dies, elementary assessment of drawing force, stress evaluation in drawing of wire, variables in wire drawing, tandem drawing process, maximum reduction of area/pass in rod drawing, deformation in wire drawing, residual stresses in rod, wire and tube drawing, defects in drawing. Tube drawing: Tube sinking, fixed and floating plug drawing, mandrel drawing, analysis in sinking, floating plug and mandrel drawing.
  
• Sheet metal forming process: Introduction, forming methods, shearing-blanking-punching-bending, spring back, elimination of spring back spinning, deep drawing, stretch forming, redrawing, reverse drawing, defects in drawing, factors affecting drawability ratio, press tool design.
  
• Unconventional Forming: Hydroforming, High Energy Rate Forming, Bulge Forming.

Module Resources

• Essential reading
  1. Course notes
• Recommended Reading
  1. Harris .J.N., Mechanical Working of Metals, Theory and Practice, Pergamon Press, 1995.
     
  2. Taylour Altan, Sook-Ik-Oh and Harold .L. Gegel – Americal Society for Metals, 1983.
     
  3. Rao .P.N., Manufacturing Technology – Tata McGraw Hill, 1991
• Journals
• Magazines
• Internet Sites
• Multimedia CDs
• Laboratory