Syllabus

Mechanical Working of Metallic Materials (MM4205) Syllabus – 36 Hrs

Module 1. Introduction and basic theories of plastic deformation: Introduction to the plastic forming of metallic materials, the flow curve, yielding criteria for ductile metals and yield locus and yield surface, Octahedral shear stress and strain, plastic stress-strain relationship, slip line field theory. 06 Hrs

Module 2. Fundamentals of metalworking: Importance of forming of metals, various methods of metalworking processes, determination of deformation and flow stresses, effect of temperature and strain rate in metalworking, important metallurgical structures of metalworking processes, friction, and lubrication, deformation zone geometry, residual stresses in metalworking, modeling of metalworking process. 08 Hrs

Module 3. Forging: Classification of forging and forging equipment, theories of forging, open and close die forging, forging defects, powder metallurgy forging, and residual stresses in forging. 05 Hrs

Module 4. Rolling: Classification of rolling and different types of rolling mills, forces, and geometrical relationships in rolling, simplified analysis of rolling variables, defects in rolled products, rolling-mill control, torque, and power in rolling. 05 Hrs

Module 5. Extrusion and Drawing of rods, wires, and tubes: Classification of extrusion and extrusion equipment, theories of extrusion, hot and cold extrusions, deformation pattern, lubrication and defects in extrusion, extrusion of tubing. Rod, wire, and tube drawing processes, analysis of rod, wire, and tube drawing, residual stresses in rod, wire, and tube drawing. 06 Hrs

Module 6. Sheet metal forming: Different sheet forming methods, analysis of bending, stretch forming, deep drawing, forming limit criteria, and defects in formed parts. 06 Hrs

To craft the practical scenario among the undergraduate students about the plastic forming of metallic materials, theories of metalworking processes and analysis of process variables that is very conventional and prevalent in Indian metalworking industries.

To develop the in-depth understanding about the mechanics of forging and rolling along with their categorization, importance, associated manufacturing problems and applications.

To understand the metalworking processes such as extrusion and drawing of rods, wires and tubes, particularly, w.r.t. their metal working mechanism, categories, associated defects and applications.

To acquire the comprehensive knowledge about sheet forming such as methods of sheet formation, analysis of bending, stretch forming, deep drawing, forming limit criteria, defects in formed parts etc.

The students will get acquaintance about the theory and practical aspects of plastic forming of metallic materials and different metal working processes that is very conventional and prevalent in Indian metalworking industries. The outcomes are as follows:

CO1
The undergraduate students will get idea about the plastic forming of metallic materials, theories of metalworking processes and analysis of process variables.

CO2
Students will develop in-depth understanding about the mechanics of hot and cold forgings, their categorization, importance, associated manufacturing problems and applications.

CO3
Students will get idea about the mechanics of rolling along with their categorization such as cold and hot rolling, importance, associated defects and applications.

CO4
Students will understand the metalworking processes of extrusion, its types such as direct and indirect extrusions, working mechanism, associated defects and engineering usefulness.

CO5
Students will know about rods, wires and tubes drawing processes, associated mechanism, mathematical formulation, defects and limitations.

CO6
Students will acquire the knowledge about sheet forming such as methods of sheet formation, analysis of sheet bending, stretch forming, deep drawing, forming limit criteria, defects in formed parts etc.

G. E. Dieter, Mechanical Metallurgy, McGraw-Hill Company , London

S. L. Semiatin, ASM Metal Handbook, Volume 14, ASM International , Title - Forming and Forging

Bert Verlinden, Julian Driver, Indradev Samajdar, Roger D. Doherty, Eds. Robert W. Cahn, Thermo-Mechanical Processing of Metallic Material, Pergamon Material Series , Elsevier, 2007

F.J. HUMPHREYS and M. HATHERLY, RECRYSTALLIZATION AND RELATED ANNEALING PHENOMENA, Elsevier , 2004