Nptel mechanical engineering manufacturing processes i. Definitions and classification of metal forming processes. Metal forming is the final stage of metallurgical manufacturing permitting to produce metal ware used in national economy as the finished products or as the billet for further processing. Metal forming processes indian institute of technology. Metal forming and machining processes springerlink. More than 90% of smelted metal is processed by different methods of metal forming. Superplastic forming an overview sciencedirect topics. The rigidplastic finiteelement method was used to analyze two new problems of metalforming processes. Metal forming is a very important manufacturing operation.
Stresses beyond yield strength of the workpiece material is required. These are casting, machining, joining welding, mechanical fastners, epoxy, etc. Manufacturing of bellows steps in manufacturing a bellows. The author has conducted research in metal forming and has taught the subjects of metal forming analysis and metal forming technology to the graduate and undergraduate students of iit bombay and iit delhi for a total period of more than 35 years, during which time, he also guided many ph. For mild steel, recrystallization temperature range may be taken as 550650c. We wish you an enjoyable and informative learning experience. Plastic properties of metals are used during the process of metal forming.
The forming processes are affected by the rates of strain used. Flow stress is the stress required to sustain a certain plastic strain on the material. Type of forming process rolling, forging, sheet metal drawing, etc. Plastics processing plastics can be machined, cast, formed, and joined with relative ease requiring little postprocessing or surfacefinish operations plastics melt or cure at relative low temperatures plastics require less energy to process than metals raw materials most commonly are pellets, powders. Forming nptel web course free ebook download as pdf file.
In metal forming industry, rolls themselves do not function in isolation. Reprint with revisions and sheet metal forming processes. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page. The rolling process is a metal forming process, in which stock of the material is passed between one or more pairs of rollers in order to reduce and to maintain the uniform thickness. Recrystallization temperature of low melting point metals like lead, zinc and tin, may be taken as room temperature. This process is also known as electromagnetic forming.
Process modeling using finite element analysis is described in one chapter and discussed in all appropriate chapters. Mechanical engineering manufacturing processes i nptel. There are four basic production processes for producing desired shape of a product. Metal spinning, also known as spin forming or spinning or metal turning most commonly, is a metalworking process by which a disc or tube of metal is rotated at high speed and formed into an axially symmetric part. Analysis and technology in metal forming 29 influence of strainrate i. Manufacturing processes i nptel online videos, courses. In a metal rolling process, rolls, stands, bearings, housing, motors, and other mechanical equipment are all a necessary part of the manufacturing operation. This is a commonly used manufacturing process that helps in manufacturing the parts for tons of known and unknown purposes. Sheet metal operations other sheet metal forming processes. Metal spinning typically involves the forming of axisymmetric components over a rotating mandrel using rigid tools or. When the force is applied by using the punch on to the sheet, the cutting or. Google books result metal formingprocesses and analysis by b.
This practical and comprehensive reference gives the latest developments on the design of sheet forming operations, equipment, tooling, and process modeling. Two prominent methods of converting raw material into a product have been metal forming and machining. Metal forming processes full notes ebook free download pdf. It is important that one chooses an effective a reliable technique based on the specific requirements of the end user. Hot working or cold working work material chemical reactivity with tool and work metals ease of application cost. High energy rate forming herf processes introduction. Stretchforming process schematicillustration of a stretchforming process. Details of high energy rate forming herf process electromagnetic forming, explosive forming electrohydraulic. It provides a detailed discussion of specific forming processes, such as deep drawing, rolling, bending extrusion and stamping. Types of press working or sheet metal operations pdf. An appropriate process model structure for the purpose of controller design for the sheet metal forming process is presented and the parameter estimation for this model is accomplished using. Sheet metal forming massachusetts institute of technology. Casting process exploit the fluidity of a metal in liquid state as it takes shape and solidifies in a mold.
Cutting and forming thin sheets of metal usually performed as cold working sheet metal 0. Spinning can be performed by hand or by a cnc lathe metal spinning does not involve removal of material, as in conventional wood or metal turning, but forming moulding of sheet. Metal forming process, mfp study materials, engineering class handwritten notes, exam notes, previous year questions, pdf free download. From flow curve, we can determine the flow stress as. When content is released on the portal, you will get an email alerting you. Lecture 1 introduction to metal forming technology lecture 2 classification of metal working processes lecture 3. Flow stress can be determined form simple uniaxial tensile test, homogeneous compression test, plane strain compression test or torsion test. Improved lubrication if lubricating film is maintained. Fundamentals of metal forming overview of metal forming material behavior in metal forming.
Superplastic forming is a specialist process used for deforming metal sheet to extremely large plastic strains to produce thinwalled components to the nearnet shape. Therefore the first step in any sheet metal process is to cut the correct shape and sized blankfrom larger sheet. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of. When you know all aspects of metal forging, you will benefit a lot if your product parts made from the metal forging process. Metal casting is a labour intensive process automation. Superplastic forming involves stretching the material at least 200% beyond its original size, although the deformation can. In forming of materials, we are concerned with flow stress of material being formed, as this affects the ability of material to undergo deformation. By mechanical working processes, the given shape and size of a machine part can be achieved with great economy in material and time. Individual chapters cover all major sheet forming processes such as blanking, bending, deep drawing, and more. This process is mainly focused on the crosssection of the ingot or the metal which is forming. Thus we have both hot and cold metal forming operations. Process design is the ensemble of operations leading from the design geometry to the dieface.
The place where all the equipment for metal rolling manufacture is set up is called a rolling mill. Metal forming is possible in case of such metals or alloys which are sufficiently malleable and ductile. Higher the rate of strain hardening, lower is the recrystallization temperature. In hot working, metal may get softened after hot deformation process. After converting nonporous metal into product form by metal forming processes, the mass as well as the volume remains unchanged. Metal forming involves changing the shape of the material by permanent plastic deformation. Fundamental concepts of metal forming technology nptel. Manufacturing processes i nptel online videos, courses iit. Metal spinning is a term used todescribe the forming of metal into seamless, axisymmetric shapes by a combination of rotational motion and force ref 14. Powder metallurgy pm is a metal working process for forming precision metal components from metal powders. Crane hook, connecting rod of ic engine, spanner, gear blanks etc.
The author highlights recent developments of metal forming technologies and explains sound, new and powerful expert system techniques for solving advanced engineering problems in metal forming. Some examples of shapes obtained by forging process. Mainly by this process, we reduce the thickness of the metal. Understanding basic principles of metal forming and further being applied by engineers and. Metal forming is the main method of making metal products and semifinished products. Thank you for signing up for our online course principles of metal forming technology. Metal forming process mfp study materials pdf free. The temperature of work is increases due to adiabatic heating. Metal forging is an integral part of any manufacturing process in the modern industrial setup. Metal in powder form is costlier than in solid form. Nptel mechanical engineering forming material behavior in metal. Lecture series on manufacturing processes i by prof.
Electromagnetic forming is a popular high energy rate forming process that uses a magnetic surge to form a sheet metal part. Technically, it is a process of synthesizing a metal object by controlling the electrodeposition of metal passing through an electrolytic solution onto a metal or metalized form. Forging is a metal working process in which useful shape is obtained in solid state by hammering or pressing metal. Stretching of the sheet during superplastic forming is much higher than with rolling and sheet forming. Typically, sheets of metal are sold as flat, rectangular sheets of standard size. In the electromagnetic process, also called magnetic pulse forming, an electric coil is placed near a metal work piece.
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