Some common metal forming processes are schematically given in fig 1. Metal forming processes such as rolling, forging, extrusion etc. Buy technology of metal forming processes by surender kumar pdf online. The process involves stretching the sheet to a calculated yield point and forming it over a tool.
Technology of metal forming processes get best books pdf. Fundamentals of metal forming overview of metal forming material behavior in metal forming temperature in metal forming. Rolling process has a high efficiency of 75 to 95% due to its low redundant deformation and smaller deformation zone geometry. Deformation results from the use of a tool, usually called a. Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. Metal forming processes indian institute of technology. It is designed for both experts and nonexperts in the forging industry. 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.
For understanding the variables of a metalforming process, it is best to consider the process as a system, as illustrated in fig. Nptel syllabus advanced manufacturing processes video course course outline the course covers the details of the advanced machining theory and practices, advanced machining processes, advanced metal forming processes, advanced welding processes and advanced foundry processes. Cutting and forming thin sheets of metal usually performed as cold working sheet metal 0. Sheet metal forming processes university of florida. The interaction of most significant variables in metal forming are shown, in a. Fundamentals of metal forming overview of metal forming material behavior in metal forming. Sold either as an individual tool or as a complete kit in a case with 7. Sheet metal forming processes mustansiriyah university. 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. The following is a brief overview of the major metal forming processes that will be covered in detail later. This is a commonly used manufacturing process that helps in manufacturing the parts for tons of known and unknown purposes. The metal spinning process is confined to concentric shapes. We feel that one should have a thorough understanding of a process before attempting numerical techniques. The common sheet metal forming products are metal desks, file cabinets, appliances, car bodies, aircraft fuselages, mechanical toys and beverage cans and many more.
Groover, fundamentals of modern manufacturing 2e material behavior in metal forming plastic region of stressstrain curve is primary interest. We aim to provide you the basic and advanced foundation of metal forging. They include a very wide range of consumer and industrial products, such as beverage cans, cookware, file cabinets, metal desks, appliances, car bodies figure 9. Download free sample and get upto 48% off on mrprental. Nptel provides elearning through online web and video courses various streams. Therefore the first step in any sheet metal process is to cut the correct shape and sized blankfrom larger sheet. Manufacturing processes i nptel online videos, courses. Classification of forming processes steady state forming processes substantially constant stress system continuous formation of product examples are rolling, extrusion, drawing, etc. Analysis and technology in metal forming 29 influence of strainrate i.
Like all forming processes, in metal spinning each unique part needs is own unique tool. Lowcarbon steel is the most commonly used sheet metal because of its low cost and. Metal forming fundamentals tutorial of manufacturing processes i course by prof d. Stretch forming is performed on a stretch press, in which a piece of sheet metal is securely gripped along its edges by gripping jaws. Casting consists of pouring molten metal into a mold, where it solidifies into the shape of the mold.
In this ebook, we will explain you all aspects of metal forging. 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. Smart material, adaptive structures and intelligent mechanical systems iitk. Sheet metal forming processes and applications asm. Read, highlight, and take notes, across web, tablet, and phone. Type of forming process rolling, forging, sheet metal drawing, etc. Aerospace metal forming technologies aries alliance shaping a better future 3. Manufacturing processes i mechanical engineering course from iit roorkee nptel lecture videos by dr. The process was well established in the bronze age beginning c.
Sheet stretch forming sheet stretch forming is a fast, economical, and accurate way to form a large panel from a metal sheet. Ppt metal forming processes powerpoint presentation. Apr 12, 2018 principles of metal forming technology. Lecture series on manufacturing processes i by prof. 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. 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. Parts that are redesigned or changed with larger dimension require new tooling. Sep 25, 2011 fundamentals of metal forming overview of metal forming material behavior in metal forming temperature in metal forming. Metal forming processes full notes ebook free download pdf. 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 term pressworking or press forming is used commonly in industry to describe general sheet forming operations, because they typically are performed on presses. It is vital to understand what constitutive relations are imbedded in a program before using it. Metal forging is a metal forming process that involves applying compressive forces to a work piece to deform it, and create a desired geometric change to the material.
Chapters also address special sheet forming operations, like spinning, incremental forming, and mechanical joining, and processes related to sheet forming, such as sheet and. For the love of physics walter lewin may 16, 2011 duration. In sheet metal forming practice, we distinguish five basic modes of deformation. Click here to visit our frequently asked questions about html5 video. The rigidplastic finiteelement method was used to analyze two new problems of metalforming processes. Plastic properties of metals are used during the process of metal forming.
Rolling is a metal forming process that deforms the work by the use of rolls. Find materials for this course in the pages linked along the left. These videos are provided by nptel elearning initiative. Ghosh,department of metallurgy and material science,iit kharagpur. Due to its low cost and generally good strength and formability characteristics, low carbon steel is the most commonly used sheet metal because high carbon composition. Manufacturing process ii fundamentals of metal forming 1. At the heart of any manufacturing system is a set of processes which change the size, shape and form of raw materials into the desirable thus giving an industrial nation the power of growing.
Metal forming is the main method of making metal products and semifinished products. Nptel mechanical engineering forming sheet metal operations. Metal forming is possible in case of such metals or alloys which are sufficiently malleable and ductile. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. Other topics include relatively new technologies, such as warm forming of magnesium and aluminum alloys, forming of advanced highstrength steels ahss, and hot stamping. Casting process exploit the fluidity of a metal in liquid state as it takes shape. Forming sheet stretch forming is a fast, economical, and accurate way to form a large panel from a metal sheet. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online. Process design is the ensemble of operations leading from the design geometry to. Your browser does not currently recognize any of the video formats available. Sheet metalworking a bending and b deep drawing c shearing. By mechanical working processes, the given shape and size of a machine part can be achieved with great economy in material and time. Manufacturing processes i nptel online videos, courses iit.
In sheet metal working, the metal being processed will have a high surface area to volume ratio. Typically, sheets of metal are sold as flat, rectangular sheets of standard size. Understanding basic principles of metal forming and further being applied by. The ultimate guide of metal forging free pdf download metal forging plays an important role in the manufacturing industry. Conventionally, spinning is the metal forming process in which the thickness of a component nominally remains constant throughout the process i. Sheet metal tools 1 roper whitney hand punch punches up to 14 hole through 16 ga. All forming methods have their own particular limitations and drawbacks. Casting processes, gating design and casting defects. Chenot cambridge university press, 2001 covers the latest numerical techniques. Transverse sheet stretch forming press fett up to 12 independently controlled axes allow for. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of. Nonsteady forming processes stress system changes continuously during the deformation process examples are forging, deep drawing, etc. Stresses beyond yield strength of the workpiece material is required. 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.
It is particularly valuable for the economical production of complex shapes, ranging from massproduced parts. Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section. The forging process is very important in industrial metal manufacture, particularly in the extensive iron and steel manufacturing industry. This is an introductory level course in manufacturing process technology and is mostly meant for undergraduate engineers. The term pressworking or press forming is used commonly in industry to describe general sheetforming operations, because they. Process design is the ensemble of operations leading from the design geometry to the dieface. Ppt metal forming processes powerpoint presentation free. Lecture notes design and manufacturing ii mechanical. Hot working and cold working operatio slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Hot working or cold working work material chemical reactivity with tool and work metals ease of application cost. Metal forming fundamentals video lecture by prof d. More than 90% of smelted metal is processed by different methods of metal forming.
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