Syllabus Metal Forming Analysis - (3171921) Credits Examination Marks Total Marks C Theory Marks Practical Marks ESE (E) PA (M) ESE (V) PA (I) 4 70 30 30 20 150 1. Introduction to hot forming, cold forming, warm forming its advantages and disadvantages Typical stress strain diagram for ductile materials Forming properties of metals and alloys (yield strength/flow stress, ductility, strain hardening, strain rate sensitivity, effect of temperature and hydrostatic pressure on yield strength) Classification of forming processes and advantages of metal forming. (Chapter - 1) 2. Stress of stress at a point, stresses on an inclined plane, Principal stress, Two dimensional Mohr’s circle for stress analysis, Deformation and strain, Stress of strain at a point. Yield conditions, Von Mises’ hypothesis of yielding, Tresca’s hypothesis of yielding, graphical representation of yield criteria, Elastic stress strain relations for isotropic elastic materials, Idealized stress strain relations in plastic deformations, Isotropic and kinematic work hardening. (Chapter - 2) 3. Introduction to; (i). Theory of slip lines, (ii). upper bound theorem and (iii). lower bound theorem. (Chapter - 3) 4. FORGING processes : Introduction, classification of forging, forging machines, metal flow in forging, Analysis of plane strain compression, analysis of compression of circular disc with slab method. (Chapter - 4) 5. EXTRUSION Processes : Introduction, calculation of extrusion load using slab method, slip line method & upper bound method. Defects in extrusion. Direct & indirect extrusion. WIRE DRAWING Processes : Introduction, defects, maximum possible reduction. Wire drawing load calculation using slab method. (Chapter - 5) 6. ROLLING Processes : Classification, types of mill, Analysis of longitudinal strip or sheet rolling process (calculation of roll separating force, torque & power, angle of bite, maximum reduction in rolling), rolling defects, roll flattening, roll camber. (Chapter - 6) 7. SHEET METAL FORMING Processes : various sheet metal operations, Blanking and punching operations, compound and progressive dies, nesting, clearance, forces in blanking, Bending of plates, bendability, spring back, bending force, bending moment for real material, stress and strain in bending, stress in deep drawing, drawability. drawing load, Anisotropy in sheetmetal. (Chapter - 7) 8. Introduction to forming limit diagram, Friction and lubrication in forming processes. (Chapter - 8)
