Forming Process also known as Metal Forming is a large set of manufacturing processes by which raw material is converted into a product. In this process, we apply stresses like tension, compression, shear, etc. to deformed the raw material. The example of forming processes are sheet metal manufacturing, forging, rolling, extrusion, wire drawing, and so on

Metal forming processes are an essential part of our society, and without them, our society would come to a grinding halt.

The products and components created by the different metal shaping techniques are used in creating everything from scaffolding and heavy machinery to designing and creating microprocessors and artificial intelligence.

When it comes to metal forming, there are several processes to choose from, with each offering its own list of benefits and detriments, each suited to certain applications, and each suited for different types of metal.

COURSE OUTLINE

Introduction to the Fundamentals of Metal Forming Processes

Fundamentals of metal forming

Types of deformation processes of metal

Bulk deformation (Rolling, Forging, Extrusion, Wire Drawing)

Sheet metal working

Stress-Strain Curve

Derivation of the relation between stress and strain

Flow stress and Average flow stress

The temperature in metal forming (Cold working and Hot-working)

Recrystallization

Iso thermal forming (recovery and Grain growth)

Strain rate Sensitivity

Rolling Process

Introduction of rolling

Shapes used for rolling

Types of rolling

Working on the rolling process

Analysis of the rolling

Rolling mills

No-Slip Point for rolling

Flatness control and rolling defect

Numerical Problems related to the rolling process

Forging Process

Introduction to forging

Classification of forging

Types of forging

Analysis of the forging

Barreling effect in forging

Open Die forging and its practices

Impression Die forging and its practices

Advantages and Limitations of Impression Die forging

Fleshless forging

Forging Press and Forging Hammers

Numerical Problems related to the forging process

Extrusion Process

Introduction to the extrusion process

Classification of extrusion

Direct and Indirect extrusion

Hot and Cold extrusion

Direct and Continuous extrusion

Analysis of the extrusion process

Effect of friction on extrusion

Extrusion Dies and Orifice

Extrusion press and other extrusion processes

Numerical Problems related to the extrusion process

Drawing Process

Introduction to Drawing

Difference between drawing and wire drawing

Bar Drawing

Wire Drawing

Features of Draw Die

Preparation of the work

Analysis of the drawing process

Sheet Metal Forming Processes

Sheet metal Cutting

Introduction to sheet metal cutting process

Characteristics of Edges

Types of sheet metal cutting

Shearing

Blanking and Punching

Clearance in Sheet metal cutting

Analysis of sheet metal cutting processes

Numerical Problems related to the sheet metal cutting process

Sheet Metal Bending

Introduction of sheet metal bending process

Types of sheet metal bending

Analysis of the sheet metal bending process

Numerical Problems related to the sheet metal bending process

Spring Back

Sheet Metal Drawing

Introduction to the drawing process

Mechanics of drawing

Stages of deformation

Analysis of the drawing process

Tests of Drawing Feasibility

Blank force and blank size determination

Numerical Problems related to the drawing process

Redrawing, Reverse Drawing and Drawing without Blank holder

Other drawing processes (Redrawing, Reverse Drawing and Drawing without Blank holder)

Defects in Drawing

The operation performed with metal tooling

Ironing

Coining & Embossing

Lancing & Twisting

The operation performed with flexible Rubber tooling

Guerin and Hydroforming process

Numerical Problems related to the other drawing processes