Advanced welding processes details of electron beam welding ebw laser beam welding lbw ultrasonic welding usw 6 4. Copper, for example, exists as nearly pure metal in certain parts of the world. Coefficients of friction in forming processes are quiet high. Yield criterion used in metal forming processes edit lesson. Under the action of such forces, the shape and size of metal. Ghosh, dept of metallurgical and materials engineering keywords. Sheet metal forming processes mustansiriyah university. Forming, metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation. Luders bands can be eliminated by coldrolling the thickness by 0. However, in the case of metal forming of porous metal. Spinning can be performed by hand or by a cnc lathe metal spinning does not involve removal of material, as in conventional wood or metal turning, but forming. The characteristics of the shop equipment for metal forming and technology of the main metal forming.
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 fundamental of metal forming theory, the theories of processes of rolling, forging and stamping as well as drawing and pressing extrusion have been given. The operations performed on the sheets to get the required shape is called sheet metal operations. Polymer manufacturing processes can be divided into continuous processes and batch processes. The characteristics of the shop equipment for metal forming and technology of the main metal forming methods have been given in separate sections. Forging is a metal working process in which useful shape is obtained in solid state by hammering or pressing metal. The author highlights recent developments of metal forming technologies and explains sound, new and powerful expert system techniques for solving advanced engineering problems in metal forming. Some examples of shapes obtained by forging process. Types of forging processes forging industry association. The forming processes are affected by the rates of strain used.
Improved lubrication if lubricating film is maintained. Application of the finite element method in metal forming. The course focuses on understanding the science and technology of different forming processes. Pdf ce6002 concrete technology ct books, lecture notes, 2marks with answers. 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. Metal forming involves changing the shape of the material by permanent plastic deformation. Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing.
In fusion welding, the metal parts to be joined are melted and then allowed to solidify pressure is not applied and filler metals may be used for this type of welding. Chapters also address special sheet forming operations, like spinning, incremental forming, and mechanical joining, and processes related to sheet forming, such as sheet and. Sheet stretch forming sheet stretch forming is a fast, economical, and accurate way to form a large panel from a metal sheet. Unfortunately, poor drawability of some materials makes it impossible to use classical forming methods. Aerospace metal forming technologies aries alliance shaping a better future 3. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of 10 1. Yieldpoint elongation lueders bands on lowcarbon steels and almg alloys. Metal spinning, also known as spin forming or spinning or metal turning most commonly, is a metalworking process by which a disc or tube of metal is rotated at high speed and formed into an axially symmetric part. Because of large reductions imparted during the extrusion process, most extrusion processes are performed hot in order to reduce the flow strength of the metal. Casting processes, gating design and casting defects.
Recent advances in metal forming processes authorstream. Finite element analysis of sheet metal forming process 60 3. Under the action of such forces, the shape and size of metal piece undergo a change. Definitions and classification of metal forming processes. Sep 09, 2016 yield criterion used in metal forming processes edit lesson. May 07, 2017 mainly sheet metal process can be divided into three types. In continuous process where raw material is fed in continuously and the product flow appears continuously e. Self reading for your interestself reading for your interest defects in metal forming processesdefects in metal forming processes and their remedies. This stress is maximum along the plane is called shear plane. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses.
In these cases, forming in higher temperatures 79, superplastic forming spf 10 11, high. Sheetmetal characteristics elongation the capability of the sheet metal to stretch without necking and failure. The term pressworking or press forming is used commonly in industry to describe general sheet forming. Metal forming and machining processes springerlink. Forming nptel web course free ebook download as pdf file. Metal casting processes indian institute of technology. It provides a detailed discussion of specific forming processes, such as deep drawing, rolling, bending extrusion and stamping. The overall investment of underground machine hall is less than those of the superstructure of a surface power house of similar dimensions. Module 3 selection of manufacturing processes nptel. The metal is heated in an oven until it melts, and the molten metal. Metal casting processes indian institute of technology guwahati. The conventional hydroelectric power stations are usually located overground at the foot of a dam or a hill slope on the banks of a river.
Rolling process has a high efficiency of 75 to 95% due to its low redundant deformation and smaller deformation zone geometry. Manufacturing technology 1 notes pdf mt 1 pdf notes book starts with the topics joining processes,classification of welding process. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 7 of. The tool will cut or shear off the metal, provided. The rigidplastic finiteelement method was used to analyze two new problems of metal forming processes. Advanced metal forming processes details of high energy rate forming herf process electromagnetic forming, explosive forming electrohydraulic forming stretch forming 4. Metal forming processes such as rolling, forging, extrusion etc. Understanding basic principles of metal forming and further being applied by.
Forming operates on the materials science principle of plastic deformation, where the physical shape of a material is permanently. Module 3 selection of manufacturing processes lecture 6 design for powder metallurgy instructional objectives by the end of this lecture, the student will learn the basic principles of powder metallurgy processes and the critical issues to be considered during design of parts to be manufactured using powder metallurgy processes. Press working operations or sheet metal operations. Cutting and forming thin sheets of metal usually performed as cold working sheet metal 0. Inspired by the forming strategies used in other sheet forming processes, such as sheet metal spinning, multistage forming strategies were recently developed in isf to improve the. Powder metallurgy pm is a metal working process for forming precision metal components from metal powders.
Manufacturing technology 1 pdf notes mt 1 notes pdf. 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. Sep 25, 2011 fundamentals of metal forming overview of metal forming material behavior in metal forming temperature in metal forming. Stresses beyond yield strength of the workpiece material is required. 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. Sheet metal fabrication process stepbystep explained types of sheet metal operations. Fundamentals of manufacturing processes 64,282 views. The process involves stretching the sheet to a calculated yield point and forming it over a tool. Cold working may be defined as plastic deformation of metals and alloys at a temperature below the recrystallization temperature for that metal or alloy.
Metal forming processes full notes ebook free download pdf. Definition of tooling geometry sheet metal forming processes are the complex interaction between specimen geometry, tolerance, surface topology, etc. After converting nonporous metal into product form by metal forming processes, the mass as well as the volume remains unchanged. Finite element analysis of sheet metal forming process.
Self reading for your interestself reading for your interest defects in metal forming processesdefects in metal forming processes. Ppt metal forming processes powerpoint presentation. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of. Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section.
Principles of metal forming technology course swayam. Here you can download the free lecture notes of manufacturing technology 1 pdf notes mt 1 notes pdf materials with multiple file links to download. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 1 of sheet metal operations other sheet metal forming processes r. If coefficient of friction becomes very high it leads to a situation called sticking friction. The first one is sheet metal cutting, second one is sheet metal bending or forming and the last one is known as deep drawing. Metal casting is a labour intensive process automation. Abb provides robot solutions for every metal fabrication application. Manufacturing processes i nptel online videos, courses. If the material of the workpiece is ductile, the material flows plastically along the shear plane, forming chip, which flows upwards along the face of the tool. 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.
Sheet metal operations i lecture 38 sheet metal operations ii lecture 39 powder metallurgy forming i lecture 40 powder metallurgy forming ii. Conclusion hydroforming is an innovative forming process hydroforming is becoming more popular i. 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. Metal spinning is a term used todescribe the forming of metal into seamless, axisymmetric shapes by a combination of rotational motion and force ref 14. Sheet metal forming massachusetts institute of technology. Metal forming processes full notes ebook free download pdf practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. 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. The temperature of work is increases due to adiabatic heating. This lecture describes the fundamentals of forging operation including working principles, types, properties of forged products, advantages, disadvantages an. Metal forming processes complete lecture notes ebook free download pdf.
High energy rate forming herf processes introduction. Nptel provides elearning through online web and video courses various streams. In this article we mainly focus on sheet metal cutting operations and other two we will discuss into upcoming articles. The application of the finite element method fem for the simulation of metal forming processes has provided a rational methodology for designing and optimizing these processes. Different sheet metal operations with diagrams guide by tips. Steel is such an important material because of its tremendous. Introduction to casting processes metal casting process begins by creating a mold, which is the reverse shape of the part we need. The forging process is very important in industrial metal manufacture, particularly in the extensive iron and steel manufacturing industry. Electromagnetic forming em forming or magneforming is a type of high velocity, cold forming process for electrically conductive metals, most commonly copper and aluminium. Metal forming is a very important manufacturing operation. Mainly sheet metal process can be divided into three types. Comparison of metal forming processescomparison of metal forming processes 34. Chandramouli associate deanresearch sastra university, thanjavur6 401.
Hot working and cold working operatio slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Lecture notes on veer surendra sai university of technology. Thus the metal gets compressed very severely, causing shear stress. Press working operations are also known as sheet metal operations. The term pressworking or press forming is used commonly. 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 spinning typically involves the forming of axisymmetric components over a rotating mandrel using rigid tools or rollers.
Sheet metal forming methods are one of the most popular processes of obtaining finished products, especially in aerospace, automobile, and defense industries. Fundamental concepts of metal forming technology nptel. Advances in sheet metal forming technologies 63 fig. 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. The mould is made from a refractory material, for example, sand. Sheet metal forming processes and applications asm. Metal in powder form is costlier than in solid form. January 27 pdf gate mathematics by s k mondals 20 years question answers. Many new casting processes have been developed which can take into consideration the aspects of dimensional accuracy and surface finish. You can implement them at any level you like from an individual palletizing cell to a complete automated production facility integrating material flow and final product inspection. Manufacturing technology 1 notes pdf mt 1 pdf notes book starts with the topics joining processes,classification of welding process,fusion welding,plastic welding,gas welding technique,oxy. Lecture series on manufacturing processes i by prof. Sheet metal forming processes ksu college of engineering ie department 9 2 single action deep drawing process singleaction drawingwith a draw cushion works the other way round the forming.
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