Introduction to Metal Forming:
Classification ofmetalforming processes, advantages and limitations, stress-strainrelations in elastic and plastic deformation.Concepts of true stress, true strain, triaxial& biaxial stresses. Determination of flow stress,principal stresses, yield criteria and their significance,Tresca& Von-Mises yield criteria, concepts of plane stress & plane strain.Deformation mechanisms, Hot and Cold working processes and its effectonmechanical properties.
Effects of Parameters:
Metallurgical aspects of metal forming, slip, twinning mechanics of plastic deformation, Effects of Temperature, strain rate, friction and lubrication, hydrostatic pressure in metalworking, Deformation zone geometry, workability of materials, Residual stresses in wrought products.
Forging:
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.
Rolling:
Classification of rolling processes. Types of rolling mills, expression for rolling load. Roll separating force. Frictional losses in bearing, power required in rolling, effects of front & back tensions, friction, friction hill. Maximum possible reduction. Defects in rolled products. Rolling variables. Simple problems.
Drawing:
Drawingequipment& 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.
Extrusion:
Types of extrusion processes, extrusion equipment & dies, deformation, lubrication & defects in extrusion. Extrusion dies, extrusion of seamless tubes. Extrusion variables. Simple problems.
Sheet Metal Forming:
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 &Powder Metallurgy: 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.
Course outcomes:
TEXT BOOKS:
1. Mechanical metallurgy (SI Units), G.E.Dieter, McGraw hill Pub-2001.
2. Production Technology (Manufacturing process, technology and Automation), R.K Jain, Khanna Publishers-2004.
3. Manufacturing Science, Amithab Gosh &A.K.Malik, East-West press 2001.
4. Production Technology Vol-II by O. P. Khanna &Lal, DhanpatRai Publications-2012.
5. A Course in Workshop Technology Vol: 1, Manufacturing Process, B.S Raghuwanshi, Published by DhanpatRai& Co (P) Ltd.-2014.
REFERENCE BOOKS
1. Materials & Process in Manufacturing – E.Paul, Degramo, J.T.Black, Ranold, A.K.Prentice-hall of India 2002
2. Elements of Workshop Technology Vol:1, S.K.Hajra Choudhury, Media Promoters & Publishers Pvt Ltd.-2008.
3. Fundamentals of Manufacturing Processes by Lal G K, Narosa
4. Textbook of Production Engineering by P. C. Sharma, S Chand & Company Ltd.