Bulk & Sheet Forming Processes For Manufacturing Engineers

Study the fundamentals related to design and manufacturing of metallic products by Bulk and Sheet metal forming methods.

What you'll learn

To become familiar with some of the basic metal forming processes like extrusion, rolling, forging, wire drawing and sheet metal working

Understand the fundamental concepts of different metal forming processes their engineering applications and limitations.

Apply their knowledge to select suitable process, variables, tooling and machines/equipment to make the products from various metal forming processes.

Determine the forces and power requirement in different metal forming processes.

Investigate defects appeared in the products manufactured by various metal forming processes and determine their causes and remedies.

Identification of metal forming parameters such as friction, temperature, the resistance of the material etc, necessary for defect free products.

Analyze the interrelationships between various factors that influence the quality of manufactured products.

Requirements

The only requirement for this course is your interest to learn the manufacturing process.

Description

The course on Metal Forming Processes is a highly valuable educational opportunity for students and professionals interested in the manufacturing industry. Metal forming processes play a critical role in the production of various products, ranging from automotive and aerospace components to household appliances. Therefore, gaining an in-depth understanding of the principles involved in shaping metals through plastic deformation is a must for individuals looking to enhance their skill set in this field.This course provides a comprehensive overview of the different types of deformation processes used in metal forming, including bulk deformation techniques such as rolling, forging, extrusion, and wire drawing, as well as sheet metal forming processes. Students will learn about the stress-strain curve, flow stress, and average flow stress, which are fundamental concepts that underpin the design and implementation of efficient manufacturing processes. Moreover, the course covers the analysis of various metal-forming operations and the equipment used in those processes.In addition to the technical aspects of metal forming, the course also covers the defects that can occur during metal forming processes and their potential solutions. This knowledge is critical in designing and implementing manufacturing processes that meet the growing demand for precision products and cost-effective production methods.Overall, the course on the Fundamentals of Metal Forming Processes is an excellent opportunity for individuals looking to pursue a career in the manufacturing industry or enhance their knowledge in this field. By enrolling in this course, students will acquire the skills and knowledge necessary to meet the increasing demand for precision manufacturing processes and become valuable assets in the industry.Reference books for this course:"Metal Forming: Mechanics and Metallurgy" by William F. Hosford and Robert M. Caddell"Sheet Metal Forming Processes and Die Design" by Vukota Boljanovic and J. R. NagyCOURSE OUTLINEIntroduction to the Fundamentals of Metal Forming ProcessesFundamentals of Metal formingTypes of deformation processes of metalBulk deformation (Rolling, Forging, Extrusion, Wire Drawing)Sheet metal workingStress-Strain CurveDerivation of the relation between stress and strainFlow stress and Average flow stressThe temperature in metal forming (Cold working and Hot-working)RecrystallizationIso thermal forming (recovery and Grain growth)Strain rate Sensitivity                                                                                                BULK-FORMING PROCESSESRolling ProcessIntroduction of rollingShapes used for rollingTypes of rollingWorking on the rolling processAnalysis of the rollingRolling millsNo-Slip Point for rollingFlatness control and rolling defectNumerical Problems related to the rolling processForging ProcessIntroduction to forgingClassification of forgingTypes of forgingAnalysis of the forgingBarreling effect in forgingOpen Die forging and its practicesImpression Die forging and its practicesAdvantages and Limitations of Impression Die forgingFleshless forgingForging Press and Forging HammersNumerical Problems Related to the forging processExtrusion ProcessIntroduction to the extrusion processClassification of extrusionDirect and Indirect extrusionHot and Cold extrusionDirect and Continuous extrusionAnalysis of the extrusion processEffect of Friction on ExtrusionExtrusion Dies and OrificeExtrusion press and other extrusion processesNumerical Problems Related to the extrusion processDrawing ProcessIntroduction to DrawingDifference between drawing and wire drawingBar DrawingWire DrawingFeatures of Draw DiePreparation of the workAnalysis of the drawing process                                                                                  SHEET METAL FORMING PROCESSESSheet metal CuttingIntroduction to sheet metal cutting processCharacteristics of EdgesTypes of sheet metal cuttingSharingBlanking and PunchingClearance in Sheet metal cuttingAnalysis of sheet metal cutting processesNumerical Problems Related to the sheet metal cutting processSheet Metal BendingIntroduction of sheet metal bending processTypes of sheet metal bendingAnalysis of the sheet metal bending processNumerical Problems Related to the sheet metal bending processSpring BackSheet Metal DrawingIntroduction to the drawing processMechanics of drawingStages of deformationAnalysis of the drawing processTests of Drawing FeasibilityBlank force and blank size determinationNumerical Problems Related to the drawing processRedrawing, Reverse Drawing, and Drawing without a Blank holderOther drawing processes (Redrawing, Reverse Drawing, and Drawing without Blank holder)Defects in DrawingThe operation performed with metal toolingIroningCoining & EmbossingLancing & TwistingThe operation performed with flexible Rubber toolingGuerin and Hydroforming processNumerical Problems related to the other drawing processesDon't miss out on the opportunity to expand your knowledge of metal-forming processes. Hurry up and enroll in this course.

Overview

Section 1: Introduction to the Fundamentals of Metal Fabrication.

Lecture 1 Introduction

Section 2: Rolling Process

Lecture 2 Introduction, Shapes, Types, Working and Analysis of Rolling Process

Lecture 3 Numerical Problems related to the Rolling Process

Section 3: Forging Process

Lecture 4 Introduction, Classification, Types and Analysis of the Forging Processes

Lecture 5 Numerical Problems related to the Forging Process

Section 4: Extrusion Process

Lecture 6 Introduction to the extrusion process

Lecture 7 Numerical Problems related to the extrusion process

Section 5: Drawing Process

Lecture 8 Introduction, Features, Preparation and Analysis of the Drawing Process

Section 6: Sheet Metal Forming Processes

Lecture 9 Introduction, Types and Analysis of the Sheet Cutting Process wit Numericals

Lecture 10 Introduction, Types and Analysis of the Sheet Bending Process wit Numericals

Lecture 11 Introduction, Stages and Analysis of the Drawing Process with Numericals

Lecture 12 Other Drawing Processes,Drawing Defects and Operations performed with Metal Tool

Lecture 13 Numerical Problems related to the other drawing processes

All concepts are introduced slowly and gradually, but comfort with thinking analytically will be helpful.,Engineers in Mechanical, Manufacturing, Industrial, Electrical and other related fields looking for a way out of traditional processes for their projects and products.,Engineering students and professionals who want to level up their skills.,Anyone starting their career in the manufacturing and production world.