PR2302 METAL FORMING TECHNOLOGY

UNIT I FUNDAMENTALS OF METAL FORMING

State of stress Components of stress, symmetry of stress tensor, principal stresses

Stress deviator von-mises, Tresca yield criteria Octahedral shear stress and shear
strain theory Flow stress determination Temperature in metal forming Hot, cold and
warm working strain rate effects metallurgical structures residual stresses Spring
back.

UNIT II FORGING AND ROLLING

Principle classification equipment tooling processes parameters and calculation

of forces during forging and rolling processes Ring compression test - Post forming
heat treatment defects (causes and remedies) applications Roll forming.

UNIT III EXTRUSION AND DRAWING PROCESSES

Classification of extrusion processes tool, equipment and principle of these processes

influence of friction extrusion force calculation defects (causes and remedies)
Rod/Wire drawing tool, equipment and principle of processes defects Tube
drawing and sinking processes mannessmann process of seamless pipe
manufacturing Tube bending.

UNIT IV SHEET METAL FORMING PROCESSES

Classification conventional and HERF processes presses types and selection of

presses formability studies FLD, Limiting Draw ratio - processes: Deep drawing,
spinning, stretch forming, plate bending, Rubber pad forming, bulging and press brake
forming Explosion forming, electro hydraulic forming, Magnetic pulse forming.

UNIT V RECENT ADVANCES

Super plastic forming Electro forming fine blanking Hydro forming Peen forming
Laser Forming Micro forming - P/M forging Isothermal forging high speed hot
forging near net shape forming high velocity extrusion CAD and CAM in forming

TEXT BOOKS
1. Dieter G.E., Mechanical Metallurgy, McGraw Hill, Co., S.I. Edition, 2001
2. Nagpal G.R. Metal forming processes, Khanna publishers, New Delhi, 2004

REFERENCES
1. Serope Kalpakjian, Steven R Schmid, Manufacturing Process for Engineering Materials
Pearson Education, 4th Edition, 2003.
2. Rao, P.N. Manufacturing Technology, TMH Ltd., 2003
3. Edward M.Mielink, Metal working science Engineering, McGraw Hill, Inc, 2000.
4. Metal Hank book Vol.14, Forming and Forging, Metal Park, Ohio,USA, 1990