Forging process is simulated and results are analyzed. Metal forming involves changing the shape of the material by permanent plastic. Worlds best powerpoint templates crystalgraphics offers more powerpoint templates than anyone else in the world, with over 4 million to choose from. In the rigidviscoplastic domain, the finite element method is being utilized as a forming process simulation tool, and in elastic and thermal domains, the method is being applied in. Mechanical engineering manufacturing processes i nptel. Metal forming is possible in case of such metals or alloys which are sufficiently malleable and ductile. Nptel mechanical engineering manufacturing processes i. Friction can also result in heating and increase in internal energy of workpiece. Stress, strain, elasticity and plasticity stress transformation and mohr s circle. The forming processes are affected by the rates of strain used.
Most sheet metal components are made by deep drawing, which requires expensive tooling. Machining processes, which include cutting, grinding, and various nonmechanical chipless processes, are desirable or even necessary for the following basic reasons. The present course intends to give the exposure of various methods of producing thread, gear manufacturing processes as well as semi automats and automats and unconventional. Inspired by the forming strategies used in other sheet forming processes, such as sheet metal spinning, multistage forming strategies were recently developed in isf to improve the geometric. Definitions and classification of metal forming processes. Forming and forging processes can be difficult to position in the high value manufacturing context new materials and processes have already reshaped the manufacturing landscape despite this a range of high integrity applications will continue to need forging. 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. Unfortunately, poor drawability of some materials makes it impossible to use classical forming methods. Two different forging processes, one to produce preform and the other one is to produce final shape, are modeled. There are four basic production processes for producing desired shape of a product. Nptel video course aerospace engineering jet aircraft propulsion. Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. The material experiences plastic deformation to change the shape of the component and converted to the desired shape of the component. The two possible schemes of extrusion are presented in the picture.
Other topics include relatively new technologies, such as warm forming of magnesium and aluminum alloys, forming of advanced highstrength steels ahss, and hot stamping. Metal forming processes full notes ebook free download pdf. Deformation results from the use of a tool, usually called a. Manufacturing technology, me202e d24 notes unit v metal forming process mohammad amir, lecturer, department of mechanical engineering, bhcet, dhauj, faridabad121004 page 2 though cold work affects the recrystallisation temperature to a. They include a very wide range of consumer and industrial products, such as beverage cans, cookware, file cabinets, metal desks, appliances, car bodies figure 9. The fundamental of metal forming theory, the theories of processes of rolling, forging and stamping as well as drawing and pressing extrusion have been given. In recent years, finite element methods have been used extensively in the metalforming industry. Manufacturing technology ii me202 mechanical working of metals dr. Finite element analysis of sheet metal forming process. Under the action of such forces, the shape and size of metal piece undergo a change. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. International journal of materials forming and machining.
Metal forming and machining processes springerlink. Fundamentals of forming fundamental concepts of metal forming. Lecture 5 quasistatic processes, zeroth law of thermodynamics and. Processes and analysis betzalel avitzur snippet view 1968. An elastic deformation disappears when the load is removed. The state variable when formulating the mathematica. The rigidplastic finiteelement method was used to analyze two new problems of metalforming processes. The conference will focus on the advanced problems from. Enter your mobile number or email address below and well send you a link to download the free kindle app. Although many new flexible forming processes have been invented, they have largely not had industrial application, so it would be valuable if intelligent means to design new processes existed. Forming processes intro forming processes metal forming. Forming nptel web course free ebook download as pdf file.
Me 206 manufacturing processes 1 department academic. Final shapes at the end of the stroke are shown in the figure 6. Lecture 57 enthalpy of formation and combustion, adiabatic flame. Ppt metal forming processes powerpoint presentation. Fundamental concepts of metal forming technology nptel. Forming processes include stamping, rolling, extrusion and forging, where deformation is induced by external compressive forces or stresses exceeding the yield stress of the material. Metal forming is a manufacturing process in which forces are applied on raw material such that stresses induced in the material are greater than yield stress and less than ultimate stress.
The term plastic deformation describes permanent shape change, in contrast to elastic deformation. Sheet metal forming processes and applications asm. Metal forming analysis the introduction of numerical methods, particularly. About 5 to 10% of the work is stored within as internal energy. The book emphasizes the analysis of forming processes and the developments in metal forming technology. More than 90% of smelted metal is processed by different methods of metal forming. Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section. Unsourced material may be challenged and removed january 2012 learn how and when to remove this template message. Advanced foundry processes metal mould, continuous, squeeze, vacuum mould, evaporative pattern, and ceramic shell casting. Process modeling using finite element analysis is described in one chapter and discussed in all appropriate chapters. Please help improve this article by adding citations to reliable sources. Metal formingintroduction to deformation processes a forming operation is one in which the shape of a metal sample is altered by plastic deformation.
Spinning can be performed by hand or by a cnc lathe. The members of scientific committee are highly experienced professionals from. Winner of the standing ovation award for best powerpoint templates from presentations magazine. The course is meant as an introduction towards primary manufacturing processes such as casting, forming and welding. Manufacturing processes ii nptel online videos, courses. Nptel an indian online short term course initiative. Sheet metal forming processes and applications pdf download.
Manufacturing process ii fundamentals of metal forming 1 introduction metal forming includes a large group of manufacturing processes in which plastic deformation is used to change the shape of metal workpieces. Theyll give your presentations a professional, memorable appearance the kind of sophisticated look that todays audiences expect. Advances in sheet metal forming technologies 63 fig. An analysis of metal forming processes using large deformation elastic plastic formulations jungho cheng and noboru kikuchi department of mechanical engineering and applied mechanics, the university of michigan, ann arbor, mi 48109.
Forming process requires stress above flow stress of the material being deformed. Metal forming is a very important manufacturing operation. Stretch forming bending process shearing process these categories are. The characteristics of the shop equipment for metal forming and technology of the main metal forming methods have been given in separate sections. Finite element analysis of sheet metal forming process 60 3. The formability and machinability of all materials is considered, including metals, polymers, ceramics, composites, biomaterials, nanomaterials, etc. Advanced machining processes introduction process principle. If coefficient of friction becomes very high it leads to a situation called sticking friction. Metal forming is the main method of making metal products and semifinished products. The effect of external work done on work piece during forming is converted into heat.
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. Manufacturing processes i nptel online videos, courses. Chapters also address special sheet forming operations, like spinning, incremental forming, and mechanical joining, and processes related to sheet forming, such as sheet and. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 7 of. Coefficients of friction in forming processes are quiet high. Plastic properties of metals are used during the process of metal forming. The term pressworking or press forming is used commonly in industry to describe general sheetforming operations, because they. Processes and analysis textbook binding january 1, 1968 by avitzur, betzalel, author see all 2 formats and editions hide other formats and editions. Analysis of this model by means of a computer provides numerical data on the forming process. The temperature of work is increases due to adiabatic heating. Manufacturing process ii fundamentals of metal forming 1.
The international journal of materials forming and machining processes ijmfmp is a refereed journal that publishes high quality articles with an emphasis on research and development in forming materials and machining processes. Nptel provides elearning through online web and video courses various streams. Pdf sheet metal products are used extensively in aerospace and automobile. Then you can start reading kindle books on your smartphone, tablet, or computer no kindle device required. Forming processes metal forming fundamentals plastic deformation is used to change the shape of the work piece. Numerical methods are used increasingly to optimize product design and deal with problems in metal forging, rolling, and extrusion processes.
Metal spinning does not involve removal of material, as in conventional wood. Application of the finite element method in metal forming. Metal forming processes, also known as mechanical working processes, are primary shaping processes in which a mass of metal or alloy is subjected to mechanical forces. Sheet metal forming processes and applications pdf download author. Sheet metal forming processes mustansiriyah university. Pdf modeling of metal forming and machining processes pp 2 cite as. Cutting and forming thin sheets of metal usually performed as cold working sheet metal 0. In these cases, forming in higher temperatures 79, superplastic forming spf 10 11, highenergyrate forming.
Using the finite element method in metalforming processes. Definition of tooling geometry sheet metal forming processes are the complex interaction between specimen geometry, tolerance, surface topology, etc. Lecture series on manufacturing processes i by prof. The application of the finite element method fem for the simulation of metal forming processes has provided a rational methodology for designing and optimizing these processes.
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