Syllabus

Syllabus of the course (40 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. 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. 08 Hrs
Module-2
Forging: Classification of forging and forging equipment, theories of forging, friction and lubrication, deformation zone geometry, open and close die forging, forging defects, important metallurgical structures of metalworking processes, powder metallurgy forging, and residual stresses in forging, residual stresses in metalworking, modeling of metalworking process. 08 Hrs.
Module-3
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-4
Extrusion: Classification of extrusion and extrusion equipment, theories of extrusion, extrusion forces and pressures, hot and cold extrusions, deformation pattern, lubrication and defects in extrusion, extrusion of tubing. 05 Hrs
Module-5
Drawing of rods, wires, and tubes: Rod, wire, and tube drawing processes, analysis of rod, wire, and tube drawing, limitation of drawing, defects and residual stresses in rod, wire, and tube drawing. 06 Hrs

Module-6
Sheet metal forming: Different sheet forming methods, analysis of bending and related equations, stretch forming and related equations, deep drawing and related equations, redrawing, deep drawing and texture, forming limit criteria, and defects in formed parts. 08 Hrs

To craft a practical scenario among the undergraduate students about the plastic forming of metallic materials, theories of metalworking processes, and analysis of process variables that are followed in metalworking industries.

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

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

To acquire 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 course outcomes are as follows:

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

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

CO3
Students will get an 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 process of extrusion, its types such as direct and indirect extrusions, working mechanisms, associated defects, and engineering usefulness.

CO5
Students will know about the drawing of rods, wires, and tubes, associated mechanisms, mathematical formulations, defects, and limitations.

CO6
Students will acquire 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.

George E. Dieter, Mechanical Metallurgy, McGraw-Hill Book 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