The rigidplastic finiteelement method was used to analyze two new problems of metal forming processes. The process involves stretching the sheet to a calculated yield point and forming it over a tool. Lecture notes design and manufacturing ii mechanical. The material experiences plastic deformation to change the shape of the component and converted to the desired shape of the component. Fundamentals of metal forming overview of metal forming material behavior in metal forming temperature in metal forming. Unfortunately, poor drawability of some materials makes it impossible to use classical forming methods. Manufacturing processes are classified into shaping casting, forming, joining, and coating, dividing, machining and modifying material property.
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. The aim of the paper is to explain the extraction of process parameters and their values for sheet metal operation which is the main component of the process information model and is required for automation of the manufacturing process. Plastic properties of metals are used during the process of metal forming. Mechanical engineering manufacturing processes i nptel. Different types of loading may be used depending on the process. Sheet metal forming processes sheet metal procedural. Lusas simulation was carried out to gain accurate and critical understanding of sheet forming process.
Apr 07, 20 nptel an indian online short term course initiative. Process information model for sheet metal operations. Nptel syllabus advanced manufacturing processes video course course outline. Chenot cambridge university press, 2001 covers the latest numerical techniques. Cutting and forming thin sheets of metal usually performed as cold working sheet metal 0. Sheet metal forming processes and applications asm. Metal forming processes full notes ebook free download pdf. Fundamental concepts of metal forming technology nptel. Stresses beyond yield strength of the workpiece material is required.
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. The object being electroformed can be a permanent part of the end product or can be temporary as in the case of wax, and removed later, leaving only the metal form. Casting processes, gating design and casting defects. Joining includes welding, brazing, soldering, adhesive bonding of. Metal forming processes indian institute of technology. Metal forming processes such as rolling, forging, extrusion etc. In this case, welding is performed by a flame formed by the combustion of oxygen and. Sheet metal forming processes mustansiriyah university. This procedure can form simple tubes or it can form intricate hollow tubes as shown in the following figure. As the metal enters the mold, the polystyrene foam is vaporized ahead of the advancing liquid, thus allowing the resulting mold cavity to be filled. 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 casting is a labour intensive process automation. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of. More than 90% of smelted metal is processed by different methods of metal forming.
Process design is the ensemble of operations leading from the design geometry to. Hot working and cold working operatio slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. It is vital to understand what constitutive relations are imbedded. Chapters also address special sheet forming operations, like spinning, incremental forming, and mechanical joining, and processes related to sheet forming, such as sheet and. Studies on water hammer forming on sheet metal works. Finite element analysis of sheet metal forming process. Classification of forming processes steady state forming processes substantially constant stress system continuous formation of product examples are rolling, extrusion, drawing, etc.
Definitions and classification of metal forming processes. The members of scientific committee are highly experienced professionals from. Deformation results from the use of a tool, usually called a. Kikuchi, analysis of metal forming processes reduced integration method was suggested by zienkiewicz, taylor and too 85, pawsey and clough 86, and naylor 87 to properly choose less order integration points so that there. 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. Casting and forming are categorized as zero processes as they involve only shifting of metal. In these cases, forming in higher temperatures 79, superplastic forming spf 10 11, high. Groover, fundamentals of modern manufacturing 2e material behavior in metal forming plastic region of stressstrain curve is primary interest. Please help improve this article by adding citations to reliable sources. Under the action of such forces, the shape and size of metal piece undergo a change. During joining and forming processes, the material and metallurgical properties. Metal forming is the main method of making metal products and semifinished products. The reliability of simulation depends on the accuracy of the. The case is also made that impulsebased methods such as electromagnetic metal forming has a central role in agile sheet metal manufacturing.
We use diverse software packages for sheetmetal forming. Principles of metal forming technology announcements. Nonsteady forming processes stress system changes continuously during the deformation process examples are forging, deep drawing, etc. Merklein m, allwood jm, behrens ba, brosius a, hagenah h, kuzman k, mori k, tekkaya ae, weckenmann a 2012 bulk forming of sheet. Numerical simulation of sheet metal forming processes, such as the stamping process, plays an important role in the design phase 1. Sheet metal forming processes and applications pdf download. Therefore the first step in any sheet metal process is to cut the correct shape and sized blankfrom larger sheet.
Recent advances in metal forming processes authorstream. Nptel an indian online short term course initiative. Manufacturing processes i nptel online videos, courses. Ppt metal forming processes powerpoint presentation free. Labour costs are more since manual welding is done mostly. The most important item in the analysis of a metal forming processes is the determination of the magnitude of the. The requirement of the automotive industry for light weight construction parts has been followed by the development and introduction of new sheetmetal materials like aluminium or highstrength steels. Typically, sheets of metal are sold as flat, rectangular sheets of standard size. 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.
Welding is a metal joining process in which two or more parts are joined or coalesced at. Manufacturing processes are classified into shaping casting, forming, joining, and. Metal casting processes indian institute of technology. Metal casting processes indian institute of technology guwahati. The rigidplastic finiteelement method was used to analyze two new problems of metalforming processes. The term pressworking or press forming is used commonly in industry to describe general sheetforming operations, because they typically are performed on presses. Analysis and technology in metal forming 29 influence of strainrate i. Sep 29, 2015 salient points about rollingsalient points about rolling rolling is the most extensively used metal formingrolling is the most extensively used metal forming process and its share is roughly 90% process and its share is roughly 90% the material to be rolled is drawn by means of frictionthe material to be rolled is drawn by means of friction into. Recent developments in metal forming technology lead to the development of a new group of metal forming processes entitled sheetbulk metal forming. Login with the course enrolled mail id and date of birth as password ddmmyyyy clicking on the course name will redirect to the score board. Lowcarbon steel is the most commonly used sheet metal because of its low cost and. Unsourced material may be challenged and removed january 2012 learn how and when to remove this template message. In sheet metal forming practice, we distinguish five basic modes of deformation.
Forming sheet stretch forming is a fast, economical, and accurate way to form a large panel from a metal sheet. The requirement of the automotive industry for light weight construction parts has been followed by the development and introduction of new sheet metal materials like aluminium or highstrength steels. Metal forming processes questions and answers sanfoundry. Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. The term pressworking or press forming is used commonly in industry to describe general sheet forming operations, because they typically are performed on presses. This is a commonly used manufacturing process that helps in manufacturing the parts for tons of known and unknown purposes. Roll forming process of c z cz purlin interchangeable machine the roll forming process works by passing sheet metal through a series of rollers, with each of these rollers adding shape to the metal as it. The conference will focus on the advanced problems from. Some common metal forming processes are schematically given in fig 1. Drawing, deep drawing, analysis of wire drawing process and load calculations. In metal forming, large forces are applied to the work material to deform it plastically, to get the desired product. Sep 25, 2011 fundamentals of metal forming overview of metal forming material behavior in metal forming temperature in metal forming.
Roll bonding is a joining process in which two or more metal strips or plates are. We feel that one should have a thorough understanding of a process before attempting numerical techniques. Manufacturing process ii fundamentals of metal forming 1. We use diverse software packages for sheet metal forming. These are casting, machining, joining welding, mechanical fastners, epoxy, etc.
Metal forming process forming can be defined as the process in which the desired size and shape of the object are obtained through plastic deformation of material. Sheet metal forming processes and applications pdf download author. Roll forming process of c z cz purlin interchangeable machine the roll forming process works by passing sheet metal through a series of rollers, with each of these rollers adding shape to the metal as it passes through. Progress in blankholder systems in the pulsating blankholder system the blankholder is subjected to a vibratory pulsating force. Forming nptel web course free ebook download as pdf file. Salient points about rollingsalient points about rolling rolling is the most extensively used metal formingrolling is the most extensively used metal forming process and its share is roughly 90%process and its share is roughly 90% the material to be rolled is drawn by means of frictionthe material to be rolled is drawn by means of friction into. Lecture series on manufacturing processes i by prof. Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section. 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.
Transverse sheet stretch forming press fett up to 12 independently controlled axes allow for. Click on exam scores both the assignment scores and exam score will be displayed. Sheet metalworking a bending and b deep drawing c shearing. Principle, process parameters, equipment and application of the following processes. Feasibility studies, process streamlining and predicting or compensating for springback effects are in the main concentrations here. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. Caddell solution manual principles of corrosion engineering and corrosion control zaki ahmad. The stresses induced during the process are greater than yield strength but should be less than the fracture strength. Details of high energy rate forming herf process electromagnetic forming, explosive forming electrohydraulic. The metal forging operation can only be performed by manual means. Axisymmetry element mesh and plain strain element mesh were use incorporated with slideline features to model and study the sheet metal forming process.