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Course Code

Course Title

Course Planner

Lectures

Tutorials Practicals Credits

MEC525

MECHANICS OF METAL FORMING

16845::Pankaj Kumar

Course Orientation

**1 :DISCIPLINE KNOWLEDGE, 5 :PLACEMENT EXAMINATION, 7 :COMPETITIVE EXAMINATION(Higer Education), 8
**

:COMPETITIVE EXAMINATION(Civil Services)

3.0

TextBooks

Sr No

Title

Author

Edition

Year

Publisher Name

T-1

MECHANICAL METALLURGY

GEORGE E. DIETER

3rd

2013

MCGRAW HILL EDUCATION

Year

Publisher Name

Reference Books

Sr No

Title

Author

Edition

R-1

TECHNOLOGY OF METAL

FORMING PROCESSES

SURENDER KUMAR

1st

R-2

A textbook of Production Engineering P.C. Sharma

11th

PRENTICE HALL

1982

S. CHAND & COMPANY

Relevant Websites

Sr No

Web address (only if relevant to the course)

Salient Features

RW-1

http://thelibraryofmanufacturing.com/forming_basics.html

Information and description related to Forming

RW-2

**http://www.efunda.com/formulae/solid_mechanics/mat_mechanics/calc_principal_stres Stress calculator
**

s.cfm

RW-3

**http://www.google.co.in/url?
**

Principal stresses and calculation

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%3A%2F%2Facademic.uprm.edu%2Fpcaceres%2FCourses%2FMMII%2FIMoM5A.pdf&ei=kWeEUsu1I4nGrAeRpIHoAw&usg=AFQjCNHo0WGreYWWXVAGAgO

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LTP week distribution: (LTP Weeks)

Detailed Plan For Lectures

Weeks before MTE

7

Weeks After MTE

7

Spill Over

7

0.0

0.0

3.0

. Change in grain structure with temperature Martensite in TTT diagram Lecture 5 Introduction and state of stresses(Experiments and bulk deformation processes) T-1:18 R-1:1 RW-1 Different types of Working of metal Figures of different Extruded deformation processes deforming processes. of representing different components stresses of stresses. piston Figure of stresses acting cube. Drawing processes hollow pipes and rolling Introduction and state of stresses(Temperature and crack formation) R-1:1 RW-1 Relation between temperature and cracking in deformation processes. metal deformation products like like Extrusion. Lecture 7 Stress and strain relationships and Elastic behaviours(Description of stress at a point) T-1:2 Lecture 3 Week 2 Week 3 Chapters/Sections of Other Readings.Week Lecture Number Number Broad Topic(Sub Topic) Week 1 Lecture 1 Introduction and state of stresses(Strength of material-basic assumptions) Lecture 2 Introduction and state of stresses(Elastic and plastic behavior of metals) T-1:1 Behavior of materials in Learning of material PPT and elastic and plastic region characteristics Discussion Introduction and state of stresses(Average stress and strain) T-1:1 Average stress and strain Learning of stress and strain concepts Introduction and state of stresses(Tensile deformation of ductile metals) T-1:1 Tensile deformation of metals Stress strain diagram PPT Tensile test UTM Introduction and state of stresses(Ductile vs Brittle behavior) T-1:1 RW-1 Ductile vs Brittle behavior Behavior of metals in PPT ductile and brittle region Tensile test UTM Lecture 4 Introduction and state of stresses(Cold. Planned Lecture Zero Knowledge of basics PPT and of metal forming Animations techniques and basic overview of course Component of stresses Stress-Strain diagram for ductile material Discussion Effect of temperature Figures of different on cracking in metal deformation deformation processes processes Different type of stresses (normal and shear stresses) auto mobile components made from metal forming processes like crankshaft. Text/reference Relevant Websites. Lecture 6 Introduction and state of stresses(Components and principle stresses) R-1:2 RW-1 Different components of Basic understanding Rectangular block stresses.hot and warm forming and types of stresses) R-1:1 RW-1 Cold working and Hot working Learning of PPT and recrystallisation Discussion temperature. books Audio Visual Aids. software and Virtual Labs Lecture Description Learning Outcomes Pedagogical Tool Live Examples Demonstration/ Case Study / Images / animation / ppt etc.

Tresca Yield criteria Calculation of stresses for ductile materials Discussion Equations of Von Mises and tresca Lecture 16 Yield criteria and flow rules (Combined stress test) T-1:3 Combined stress test Combination of Discussion different stresses and yield criteria Yield criteria and flow rules (Octahedral shear stress and shear strain) T-1:3 Shear stress and shear strain in Octahedral condition Knowledge about the Demonstration by calculation of stress Faculty and strain Lecture 17 Yield criteria and flow rules (Invariants of stress and strain) T-1:3 Invariants of stress and strain Invariants of stress and strain Yield criteria and flow rules (Levy Mises equation) T-1:3 Plastic stress-strain relation Levy Mises equation Discussion and demonstration by faculty Discussion Torsion test .Week 3 Week 4 Lecture 8 Stress and strain relationships and Elastic behaviours(state of stress in two and three dimensions) T-1:2 Plane stresses in two and three dimensions Calculation of stresses in two and three dimensions Lecture 9 Stress and strain relationships and Elastic behaviours(Mohr's circle of stress in two dimension) T-1:2 R-1:2 Formation of mohr's circle with numericals Calculation of Figure and stresses with the help Discussion of mohr's circle. Numerical problems Lecture 10 Stress and strain relationships and Elastic behaviours(Hydrostatics and Deviator components of stress) Stress and strain relationships and Elastic behaviours(Elastic stress strain relations) Lecture 11 Stress and strain relationships and Elastic behaviours(Calculations of stresses from elastic strains) T-1:2 RW-3 Role of Hydrostatics and Effect of stress Deviator components of components stress Sketches and Discussion T-1:2 RW-1 Stress strain relation Hooke's law T-1:2 RW-2 Numerical problems on Knowledge about Stress strain relation stress strain relationship Lecture 12 Week 5 Week 6 Figure of stresses on oblique plane Knowledge about stress strain relationship Digram between stress strain Numerical Test1 Lecture 13 Yield criteria and flow rules (Introduction) T-1:3 Yield criteria and flow rules (The flow curve) RW-1 Introduction about theory of plasticity Introduction about theory of plasticity Figure of Stress Tensile test on strain UTM curves of different materials T-1:3 Description of flow curve Knowledge about flow curve Idealized flow curve Tensile test on UTM Lecture 14 Yield criteria and flow rules (True stress and true strain) T-1:3 Relation between true stress and true strain Knowledge about stress-strain equations Discussion Equations of stress strain relation Lecture 15 Yield criteria and flow rules (Yield criteria of ductile metals) T-1:3 Von Mises or Distortion energy Criterion.

Lecture 24 Forging and rolling of metals(Analysis of Closed die forging by slab method) R-2:13 Analysis of open die forging with sticking friction Numerical problem for solving pressure distribution that is friction hill Demonstration by faculty Lecture 25 Forging and rolling of metals(Calculation of Forging loads in closed die forging) T-1:16 Calculation of Forging loads in closed-die forging Numerical Calculation of loads Numerical Lecture 26 Forging and rolling of metals(Hot rolling and cold rolling) T-1:17 RW-1 Hot and cold rolling Different types of rolling Figures of Rolling Thin sheets mill T-1:17 RW-1 Methods of rolling Different types of rolling Figures of Rolling mill R-2:13 Analysis of Rolling Derivation of rolling Demonstration by load with concepts of faculty neutral point Week 10 Lecture 28 Forging and rolling of metals(Calculation of rolling load) T-1:17 Calculation of forging load Derivation Demonstration by faculty Forging and rolling of metals(Numerical Problems) T-1:17 Numerical problem on rolling Numerical problem Demonstration by faculty Forging and rolling of metals(Equipments) Lecture 23 Forging and rolling of metals(Forging plain strain) Forging and rolling of metals(Open die and close die forging) Week 9 Forging and rolling of metals(Rolling of bar and shapes) Lecture 27 Forging and rolling of metals(Forces and geometrical relationship in rolling) Lecture 29 Test2 Engine blocks . different types of forging dies Figures of open and closed die forging.Week 6 Lecture 18 Yield criteria and flow rules (Prandtl Reuss equation) T-1:3 Plastic stress-strain relation Prandtl Reuss equation Discussion and demonstration by faculty Week 7 Lecture 19 Yield criteria and flow rules (Slip line field theory) T-1:3 Two Dimensional plastic flow Slip line field theory Methods of developing plastic constraint Sketches and Discussion SPILL OVER Week 7 Lecture 20 Spill Over Lecture 21 Spill Over MID-TERM Week 8 Lecture 22 Forging and rolling of metals(Classification of forging process) T-1:16 Different types of forging processes Uses of forging processes Figure of different Crankshafts types of forging processes T-1:16 Different types of forging equipments Uses of forging equipments Figure of different Hydraulic and types of forging mechanical equipments forging press T-1:16 Forging plain strain Calculation of forces Demonstration by in forging faculty T-1:16 Description of open and Knowledge about closed die forging.

Week 10 Lecture 30 Extrusion and Drawing (Classification of Extrusion process) T-1:18 Week 11 Lecture 31 Extrusion and Drawing (Analysis of extrusion process) Different types of extrusion and drawing processes Uses of extrusion processes Figure of different Tooth-paste types of forging processes T-1:18 Analysis of extrusion process Knowledge about different forces in extrusion Figure of stress strain distribution in partial tube Lecture 32 Extrusion and Drawing (Defects in extrusion) T-1:18 Different types of lubrication and defects in extrusion processes Knowledge about lubrication and defects in extrusion processes PPT Extrusion and Drawing (Hydrostatic extrusion) T-1:18 Use of hydro pressure in Role of hydrostatic PPT extrusion processes pressure in extrusion T-1:19 Different types of drawing processes T-1:19 Analysis of forces acting Knowledge related process forces in wire drawing Faculty demonstration by faculty T-1:19 Types of tube drawing processes PPT T-1:19 Analysis of forces acting Knowledge related during process forces in tube drawing Faculty demonstration Numerical problem on extrusion and drawing Problem solution Numerical Different types of sheet forming processes Figures of different Perforation sheet forming processes Lecture 33 Extrusion and Drawing(Rod and wire drawing) Extrusion and Drawing (Analysis of wire drawing) Week 12 Lecture 34 Extrusion and Drawing (Tube drawing process) Extrusion and Drawing (Analysis of tube drawing) Lecture 35 Extrusion and Drawing (Numerical problems) T-1:19 RW-1 RW-1 Lecture 36 Use and working of drawing process equipments Knowledge about tube drawing Wrinkles and distortion defect Figures of different drawing processes and PPT Wires Test3 Week 13 Lecture 37 Sheet metal Forming and Lubrication mechanisms (Forming methods) T-1:20 RW-1 Introduction and methods of sheet forming processes Sheet metal Forming and Lubrication mechanisms (Shearing and Blanking) T-1:20 RW-1 Introduction and Different types of methods of shearing and shearing and blanking blanking processes processes Figures of different Washers shearing and blanking processes Sheet metal Forming and Lubrication mechanisms (Bending) T-1:20 RW-1 Definition of terms used Springback in in bending bending Different types of bending processes Lecture 38 Sheet metal Forming and Lubrication mechanisms (Stretch forming) T-1:20 RW-1 Stretch forming operation Variation of necking Figures of stretching processes Sheet metal Forming and Lubrication mechanisms (Deep drawing) T-1:20 RW-1 Description of Deep drawing Analysis of deep drawing Figures of different Bottles and deep drawing processes cup Sheet metal Forming and Lubrication mechanisms (Forming limit criteria) T-1:20 RW-1 Description forming limit Analysis of forming limit Forming limit diagram .

Week 13 Lecture 39 Sheet metal Forming and Lubrication mechanisms (Lubrication principle and mechanism) Sheet metal Forming and Lubrication mechanisms (Lubrication need and their components and cost selection) Week 14 Lecture 40 Sheet metal Forming and Lubrication mechanisms (Chemical characteristics and solid lubrication) Sheet metal Forming and Lubrication mechanisms (classification of lubricants and use in forming process) R-1:7 Lubrication principle and mechanism Knowledge about lubrication mechanism Figure of three regimes of lubrication R-1:7 Need of lubrication in industries Knowledge about costs of lubrication Different components of costs in lubrication R-1:7 Chemical characteristics Types of solid values and categories of lubrication solid lubrication R-1:7 classification of lubricants SPILL OVER Week 14 Lecture 41 Spill Over Lecture 42 Spill Over Week 15 Lecture 43 Spill Over Lecture 44 Spill Over Lecture 45 Spill Over Scheme for CA: Component Test Frequency Out Of 2 3 Total :- Details of Academic Task(s) Each Marks Total Marks 10 20 10 20 Demonstration by Faculty Use of lubrication in Demonstration by forming process Faculty Grease .

Analysis of tube drawing To check the understanding of students about the topics done in class 11 / 12 .AT No. Stress tensor. Analysis of extrusion process. Cold. 9 / 10 Test3 To check student's ability to understand subject matter through written test Classification of Extrusion process. Classification of forging process. Analysis of Closed die forging by slab method. Description of stress at a point. Mohr's circle of stresstwo dimension. Temperature and crack formation. Hydrostatics and Deviator components of stress. Objective Topic of the Academic Task Nature of Academic Task (group/individuals/field work Evaluation Mode Allottment / submission Week Test1 To check student's ability to understand subject matter through written test Strength of material-basic assumptions. Rolling of bar and shapes. Invariants of stress and strain. Combined stress test. The flow curve. Rod and wire drawing. Yield Individual criteria of ductile metals. Forging plain strain. Octahedral shear stress and shear strain. Slip line field theory. Prandtl Reuss equation. Hot rolling and cold rolling. Elastic and plastic Individual behavior of metals. True stress and true strain. Levy Mises equation. Average stress and strain. Experiments and bulk deformation processes. Anistropy in yielding.hot and warm forming and types of stresses. Equipments. Hydrostatic extrusion. Components and principle stresses. Numerical Problems Answers should be to the point and problems should be solved step wise. Yield locus. Elastic stress strain relations. Calculation of Forging loads in closed die forging. state of stress in two and three dimensions. Calculation of rolling load. Tube drawing process. Calculations of stresses from elastic strains. Analysis of wire drawing. Ductile vs Brittle behavior. Open die and close die forging. Deformation lubrication and Individual Defects in extrusion. Forces and geometrical relationship in rolling. 3/4 Test2 To check the understanding of students about the topics done in class Introduction. Yield surface and normality. Tensile deformation of ductile metals. Strain energy Answers should be to the point and problems should be solved step wise.

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