JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

Course Outcomes

Student will be able to:

• 1. Understand fundamentals of metal forming and stress curves.
• 2. Know various process parameters and applied loads in sheet metal working.
• 3. Understand various forging techniques and defects in forging.
• 4. Understand principles of rolling and stresses developed under rolling loads.
• 5. Analyze Extrusion and drawing processes and associated stresses developed.

UNIT - I

Fundamentals of Metal Forming: Classification of forming processes, mechanisms of metal forming: slab method, Upper and lower bound analysis, Deformation energy method and finite element method temperature of metal working, hot working, cold working, friction and lubricants.

UNIT - II

Rolling of metals: Rolling processes, forces and geometrical relationship in rolling, simplified analysis, rolling load, rolling variables, theories of cold and hot rolling, problems and defects in rolling, torque and power calculations, Problems.

UNIT - III

Forging: Classification of forging processes, forging of plate, forging of circular discs, open die and closed-die forging, forging defects, and powder metallurgy forging. problems on flow stress ,true strain and forging load. Press tool design: Design of various press tools and dies like piercing dies, blanking dies, compound dies and progressive blanking dies, design of bending, forming and drawing dies.

UNIT - IV

Extrusion: Classification, Hot Extrusion, Analysis of Extrusion process, defects in extrusion, extrusion of tubes, production of seamless pipes. Problems on extrusion load. Drawing: Drawing of tubes, rods, and wires: Wire drawing dies, tube drawing process, analysis of wire, deep drawing and tube drawing .Problems on draw force.

UNIT - V

Sheet Metal forming: Forming methods, Bending, stretch forming, spinning and Advanced techniques of Sheet Metal Forming, Forming limit criteria, defect in formed parts. Advanced Metal forming processes: HERF, Electromagnetic forming, residual stresses, in-process heat treatment, and computer applications in metal forming. problems on Blanking force, Blank diagram in Cup Diagram, Maximum considering shear.

REFERENCES:

• 1. Fundamentals of Metal Forming Processes – B.L. Juneja
• 2. Principles of Metal Working processes - G.W. Rowe
• 3. ASM Metal Forming Hand book.