Classification of metal working processes, characteristics of wrought products, advantages and limitations of metal working processes.Concepts of true stress, true strain, triaxial & biaxial stresses. Determination of flow stress. Principal stresses, Tresca & Von-Mises yield criteria, concepts of plane stress & plane strain.
Temperature, strain rate, friction and lubrication, hydrostatic pressure in metalworking, Deformation zone geometry, workability of materials, Residual stresses in wrought products.
Classification of forging processes. Forging machines & equipment. Expressions for forging pressures & load in open die forging and closed die forging by slab analysis, concepts of friction hill and factors affecting it. Die-design parameters. Material flow lines in forging. Forging defects, Residual stresses in forging. Simple problems.
Classification of Rolling processes. Types of rolling mills, expression for RoIling load. Roll separating force. Frictional losses in bearing etc, power required in rolling, Effects of front & back tensions, friction, friction hill. Maximum possible reduction. Defects in rolled products. Rolling variables, simple problems.
Drawing equipment & dies, expression for drawing load by slab analysis, power requirement. Redundant work and its estimation, optimal cone angle & dead zone formation, drawing variables, Tube drawing, classification of tube drawing, simple problems.
Types of extrusion processes, extrusion equipment & dies, deformation, lubrication & defects in extrusion. Extrusion dies, Extrusion of seamless tubes. Extrusion variables, simple problem
Forming methods, dies & punches, progressive die, compound die, combination die. Rubber forming. Open back inclinable press (OBI press), piercing, blanking, bending, deep drawing, LDR in drawing, Forming limit criterion, defects of drawn products, stretch forming. Roll bending & contouring, Simple problems
High Energy Rate forming Methods: Principles, advantages and applications, explosive forming, electro hydraulic forming, Electromagnetic forming. Powder metallurgy: Basic steps in Powder metallurgy brief description of methods of production of metal powders, conditioning and blending powders, compaction and sintering application of powder metallurgy components, advantages and limitations.