Unit 1 Introduction to hot forming, cold forming, warm forming its advantages and disadvantages

4 lecture hours

• and its effect on mechanical properties
• Typical stress strain diagram for ductile materials
• Description of Material properties of metals and alloys (yield strength/flow stress
• strain hardening
• strain rate sensitivity
• effect of temperature
• lubrication and hydrostatic pressure on yield strength)
• Tensile test
• effect of properties on forming
• Classification of forming processes and advantages of metal forming

Unit 2 Stress of stress at a point, stresses on an inclined plane, Principal stress, Two dimensional

3 lecture hours

• Mohr’s circle for stress analysis
• Deformation and strain
• Stress of strain at a point
• Bauschinger effect modeling
• effective stress and strain

Unit 3 Yield conditions, Von Mises’ hypothesis of yielding, Tresca’s hypothesis of yielding,

3 lecture hours

• graphical representation of yield criteria
• Elastic stress strain relations for isotropic elastic materials
• Idealized stress strain relations in plastic deformations
• Isotropic and kinematic work hardening

Unit 4 Introduction to; (i). Theory of slip lines, (ii). upper bound theorem and (iii). lower bound

3 lecture hours

• Stamping analysis: 2-D and 3-D model of stamping
• stretch and draw ratios in stamping
• Load instability and tearing: uniaxial tension of perfect strip and imperfect strip
• tensile instability in stretching continuous sheet

Unit 5 Sheet metal forming

• various sheet metal operations
• Blanking and punching operations
• compound and progressive dies
• forces in blanking
• Bending of plates
• spring back
• bending force
• bending moment for real material
• stress and strain in bending
• stress in deep drawing
• drawability. drawing load
• Anisotropy in sheetmetal
• Sheet formability: Forming limit curve – concept and evaluation
• formability tests
• theoretical 10 Subject Code: 3162512 w.e.f
• AY 2018-19 prediction
• factors affecting FLC

Unit 6 Forging

5 lecture hours

• classification of forging
• forging machines
• metal flow in forging
• Analysis of plane strain compression
• analysis of compression of circular disc with slab method

Unit 7 Extrusion

5 lecture hours

• calculation of extrusion load using slab method
• slip line method & upper bound method
• Defects in extrusion
• Direct & indirect extrusion
• WIRE DRAWING Processes: Introduction
• maximum possible reduction
• Wire drawing load calculation using slab method

Unit 8 Rolling

5 lecture hours

• types of mill
• Analysis of longitudinal strip or sheet rolling process (calculation of roll separating force
• torque & power
• angle of bite
• maximum reduction in rolling)
• rolling defects
• roll flattening
• roll camber

Unit 9 Advancement in metal forming

• High Energy Rate Forming Methods: Principles
• advantages and applications
• explosive forming
• electro hydraulic forming
• Electromagnetic forming
• tailor welded blanks
• friction stir welding of sheets. 4 Total