Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section. Forming hinges in the punch press saves time, increases accuracy duration. Reprint with revisions and sheet metal forming processes. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. Module 3 selection of manufacturing processes nptel. Casting processes, gating design and casting defects. The rolling process is a metal forming process, in which stock of the material is passed between one or more pairs of rollers in order to reduce and to maintain the uniform thickness. It is the oldest and most basic of the production rubberpad forming processes. Metal forming technology classification of metal working processes. Explosive forming is best described as a these shortrun applications are the short lead process in which metal parts are formed by the times required and minimum expenditures for high pressures resulting from the detonation of tooling. Manufacturing processes i nptel online videos, courses. Even though roll forging uses rolls in order to accomplish the deformation of the material, it is classified as a metal forging process and not a rolling process.
Mechanical engineering manufacturing processes i nptel. Metal casting is a labour intensive process automation. Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. Plastic properties of metals are used during the process of metal forming. There are four basic production processes for producing desired shape of a product. Process description and analysis of forging, rolling, extrusion, drawing and sheet metal forming processess such as deep drawing, bending, shearing and. The electromagnetic forming process emf is a highly dynamic process using pulsed mag netic f ields to form metals with high electrical conductivity such as aluminium. Other machining operations shaping and planing a singlepoint tool moves linearly relative to the work part shaping a tool moves. Metal forming is the main method of making metal products and semifinished products.
If coefficient of friction becomes very high it leads to a situation called sticking friction. In forming processes, such as forging, the instantaneous flow stress can be found from the flow curve, as the stress required to cause a given strain or deformation. 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. Stretching of the sheet during superplastic forming is much higher than with rolling and sheet forming.
Other sheet metal forming operationsquiz questions. Sheet metal forming is a process of shaping thin sheets of metal by applying metal formingprocesses and analysis by b. 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. Improved lubrication if lubricating film is maintained. Thus we have both hot and cold metal forming operations. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page. For mild steel, recrystallization temperature range may be taken as 550650c. What is forging process, operation, types, application. Superplastic forming is a specialist process used for deforming metal sheet to extremely large plastic strains to produce thinwalled components to the nearnet shape. What are the requirements for superplastic forming.
The guerin process, also called guerin stamping, is a manufacturing process used in the shaping of sheet metals. Nptel mechanical engineering forming oint initiative of iits and iisc. As it rotates around a single axis, heat is applied to the mold. In sheet metal forming practice, we distinguish five basic modes of deformation. Metal forming is the approach of creating the metallic components by deforming the metal but not by removing, cutting, shredding or breaking any part. Metal forming processes full notes ebook free download pdf. Jan 01, 20 conclusion hydroforming is an innovative forming process hydroforming is becoming more popular i. Of these manufacturing processes, forming is a widely used process which finds applications in automotive, aerospace, defense and other industries.
Nptel mechanical engineering manufacturing processes i. The characteristics of the shop equipment for metal forming and technology of the main metal forming methods have been given in separate sections. Manual metal spinning and power spinning are generally in competition with pressing and deep drawing. Lecture series on manufacturing processes i by prof. 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. Effect of strain rate on forming process higher the rate of strain hardening, lower is the recrystallization temperature. Recrystallization temperature of low melting point metals like lead, zinc and tin, may be taken as room temperature. Sheet metal operations other sheet metal forming processes. Superplastic forming an overview sciencedirect topics. Materials which do not become brittle at higher strain rates alone can be explosive formed. Fundamentals of manufacturing processes 64,357 views 32. In the pres s forming process, aqueous slurry of fibers is agit ated and poured into a mold, pressure is appl ied to. Plastics processing plastics can be machined, cast, formed, and joined with relative ease requiring little postprocessing or surfacefinish operations plastics melt or cure at relative low temperatures plastics require less energy to process than metals raw materials most commonly are pellets, powders.
Colton 26 flat rolling analysis results without front and back tension p p p p. Sep 29, 2015 comparison of metal forming processescomparison of metal forming processes 34. The workpiece is completely or partially subjected to plastic deformation during the forming operation. Mechanical working requires that the material may undergo plastic deformation during its processing. Thus, at room temperature, conventional steels consist of a mixture of cementite and ferrite essentially iron. This is not usually possible with the vacuum forming process. Rolling is a process that is widely used and has very high production. By using air pressure on the back side of the sheet during the forming process, textures, undercuts and injection molding details can be achieved. Metal forming processes indian institute of technology. Principles of metal forming technology course swayam. Advances in metal forming expert system for metal forming.
Process design is the ensemble of operations leading from the design geometry to the dieface. Metal forming operations which cause significant shape change by plastic deformation in metallic parts are referred to bulk deformation processes. Stretchforming process schematicillustration of a stretchforming process. Stresses beyond yield strength of the workpiece material is required. Apr 24, 2017 forging is a metal forming process in which the metal is heated and a force is applied in such a way that a required shape can be obtain.
Manufacturing of bellows steps in manufacturing a bellows. Metal forming is possible in case of such metals or alloys which are sufficiently malleable and ductile. Rolling, forging, extrusion and drawing are bulk forming processes. Nptel provides elearning through online web and video courses various streams. Sheet metal forming massachusetts institute of technology. Process design is the ensemble of operations leading from the design geometry to. In secondary forming, the raw materials, such as blooms, billets are converted into finished parts such as gears, wheels, spanners etc.
Little or no material is removed during the forming process. Jul 27, 2009 lecture series on manufacturing processes i by prof. Google books result metal formingprocesses and analysis by b. Superplastic forming involves stretching the material at least 200% beyond its original size, although the deformation can. Self reading for your interestself reading for your interest defects in metal forming processesdefects in metal forming processes and their remedies. 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. Understanding basic principles of metal forming and further being applied by engineers and.
Definitions and classification of metal forming processes. Apr 12, 2018 principles of metal forming technology. It is basically a hot working process in which the work piece is heated up to plastic stage and the force is applied by manually or by press according to the requirement. In this sheet metal high velocity forming, the electrical energy stored in a series of capacitors is. The temperature of work is increases due to adiabatic heating. Pressure forming can achieve the high quality and detailed look of injection molding, without the expensive tooling costs. The centrifugal casting process, that is also called centrifugal molding, is a method of forming plastic in which a dry or liquid plastic is placed in a rotating mold such as a pipe chapter. Metal in powder form is costlier than in solid form. Metal forming processes such as rolling, forging, extrusion etc. In this process, the workpiece in the form of slab or plate is. It provides a detailed discussion of specific forming processes, such as deep drawing, rolling, bending extrusion and stamping.
The forming mandrel is mounted on the headstock of a lathe. In extrusion, for example, the flow stress considerably changes during the forming process as the material gets work hardened considerably. Metal casting processes indian institute of technology guwahati. High energy rate forming herf processes introduction. Fundamental concepts of metal forming technology nptel. The present module describes the salient aspects of forging process. This process is also known as electromagnetic forming. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 7 of 10 friction. Nptel mechanical engineering forming analysis of forming slab method r. Powder metallurgy pm is a metal working process for forming precision metal components from metal powders. 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. Avitzur facebook introduction to sheet metal forming processes metal forming processes.
The forming processes are affected by the rates of strain used. More than 90% of smelted metal is processed by different methods of metal forming. Roll forging roll forging or roll forming is a forging technique that utilizes opposing rolls to shape a metal part. Coefficients of friction in forming processes are quiet high. Forming nptel web course free ebook download as pdf file. A simple tool and sheet preform setup for manual metal spinning is shown in fig. Sheet metal operations other sheet metal forming processes nptel. Cutting and forming thin sheets of metal usually performed as cold working sheet metal 0.
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