Process design is the ensemble of operations leading from the design geometry to. It is basically a hot working process in which the work piece is heated up to plastic stage and the force is applied by manually or by press according to the requirement. A bank of capacitors is first charged with high voltage, and then discharged across a gap between two electrodes. Sep 25, 2011 fundamentals of metal forming overview of metal forming material behavior in metal forming temperature in metal forming. Jul 27, 2009 lecture series on manufacturing processes i by prof. Salient points about rollingsalient points about rolling rolling is the most extensively used metal formingrolling is the most extensively used metal forming process and its share is roughly 90%process and its share is roughly 90% the material to be rolled is drawn by means of frictionthe material to be rolled is drawn by means of friction into. The rolling process is a metal forming process, in which stock of the material is passed between one or more pairs of rollers in order to reduce and to maintain the uniform thickness. Mainly sheet metal process can be divided into three types. Rolling, forging, extrusion and drawing are bulk forming processes. Metal forming is the approach of creating the metallic components by deforming the metal but not by removing, cutting, shredding or breaking any part. Mechanical engineering manufacturing processes i nptel.
Process description and analysis of forging, rolling, extrusion, drawing and sheet metal forming processess such as deep drawing, bending, shearing and. The ability of materials to exhibit extensive plastic deformation generally the elongation is over 200% at an elevated temperature t 0. Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. Metal forming is the main method of making metal products and semifinished products. Of these manufacturing processes, forming is a widely used process which finds applications in automotive, aerospace, defense and other industries. Improved lubrication if lubricating film is maintained. Bending, spinning, drawing, and stretching are a few important metal forming process in manufacturing. Avitzur facebook introduction to sheet metal forming processes metal forming processes.
Metal forming processes indian institute of technology. Roll forming process of c z cz purlin interchangeable machine the roll forming process works by passing sheet metal through a series of rollers, with each of these rollers adding shape to the metal as it passes through. There are four basic production processes for producing desired shape of a product. High energy rate forming herf processes introduction. In this article we mainly focus on sheet metal cutting operations and. Ppt metal forming processes powerpoint presentation free. Effect of strain rate on forming process higher the rate of strain hardening, lower is the recrystallization temperature. Metal forming and machining processes springerlink. Thefigse fine precipitate particles act as barriers to the motion of dislocations and provide resistance to slip, thereby increasing the strength and hardness. Metal casting processes indian institute of technology guwahati. Metal forming metal forming is a general term for a large group, that includes a wide variety of manufacturing processes. This process is also known as electromagnetic forming. Sep 29, 2015 salient points about rollingsalient points about rolling rolling is the most extensively used metal formingrolling is the most extensively used metal forming process and its share is roughly 90% process and its share is roughly 90% the material to be rolled is drawn by means of frictionthe material to be rolled is drawn by means of friction into.
In extrusion, for example, the flow stress considerably changes during the forming process as the material gets work hardened considerably. Sequential process design manufacturing waste resource, waste time concurrent process all disciplines are involved in the earliest stages of product design progress concurrently so iterations results in less wasted effort and time key to success. Roll forming process of c z cz purlin interchangeable machine the roll forming process works by passing sheet metal through a series of rollers, with each of these rollers adding shape to the metal as it. Metal forming involves changing the shape of the material by permanent plastic deformation. The non grooved portion of the rolls revolution is useful for feeding the stock during the process. Metal in powder form is costlier than in solid form. Forming nptel web course free ebook download as pdf file. Apr 12, 2018 principles of metal forming technology. The overall investment of underground machine hall is less than those of the superstructure of a surface power house of similar dimensions. Recrystallization temperature of low melting point metals like lead, zinc and tin, may be taken as room temperature. After converting nonporous metal into product form by metal forming processes, the mass as well as the volume remains unchanged.
Stretching of the sheet during superplastic forming is much higher than with rolling and sheet forming. Nptel provides elearning through online web and video courses various streams. Cutting and forming thin sheets of metal usually performed as cold working sheet metal 0. Thus we have both hot and cold metal forming operations. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. Stresses beyond yield strength of the workpiece material is required. Metal casting is a labour intensive process automation. Design and manufacturing sequential process design manufacturing waste resource, waste time concurrent process all disciplines are involved in the earliest stages of product design progress concurrently so iterations results in less wasted effort and time key to success. For mild steel, recrystallization temperature range may be taken as 550650c. Definitions and classification of metal forming processes.
Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section. In sheet metal forming practice, we distinguish five basic modes of deformation. In this article we mainly focus on sheet metal cutting operations and other two we will discuss into upcoming articles. Explosive forming is best described as a these shortrun applications are the short lead process in which metal parts are formed by the times required and minimum expenditures for high pressures resulting from the detonation of tooling. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 7 of 10 friction. Colton 2 overview process equipment products mechanical analysis. Manufacturing processes i nptel online videos, courses. Sheet metal operations other sheet metal forming processes. Superplastic forming is a specialist process used for deforming metal sheet to extremely large plastic strains to produce thinwalled components to the nearnet shape. Reprint with revisions and sheet metal forming processes.
Metal forming processes full notes ebook free download pdf. Smith forging is traditional method of metal forming. Roll forging or roll forming is a forging technique that utilizes opposing rolls to shape a metal part. A material removal process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains most common application. These manufacturing process som study notes will help you to get conceptual deeply knowledge about it. Other sheet metal forming operationsquiz questions. Mostly these products do not need any finishing process. Google books result metal formingprocesses and analysis by b. Module 3 selection of manufacturing processes nptel. In this process, an impulse current is employed to. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page. The author highlights recent developments of metal forming technologies and explains sound, new and powerful expert system techniques for solving advanced engineering problems in metal forming.
In secondary forming, the raw materials, such as blooms, billets are converted into finished parts such as gears, wheels, spanners etc. Lecture 1 introduction to metal forming technology. It provides a detailed discussion of specific forming processes, such as deep drawing, rolling, bending extrusion and stamping. Electromagnetic forming emf is a noncontact forming technique. Sheet metal forming is a process of shaping thin sheets of metal by applying metal formingprocesses and analysis by b. Apr 24, 2017 forging is a metal forming process in which the metal is heated and a force is applied in such a way that a required shape can be obtain. Sheet metal forming massachusetts institute of technology. The temperature of work is increases due to adiabatic heating. In this process, the workpiece in the form of slab or plate is. The first one is sheet metal cutting, second one is sheet metal bending or forming and the last one is known as deep drawing. It is an impulse or highvelocity forming method using pulsed magnetic field by application of lorentz forces to the work piece preferably made of highly electrically conductive material without having working medium and mechanical contact.
Advances in metal forming expert system for metal forming. Superplastic forming involves stretching the material at least 200% beyond its original size, although the deformation can. The forming processes are affected by the rates of strain used. In this sheet metal high velocity forming, the electrical energy stored in a series of capacitors is. Sintering process enhances the density of the final part by filling up the incipient holes and increasing the area of contact among the powder particles in the compact perform. Hot working and cold working operatio slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising.
Rolling is a process that is widely used and has very high production. Fundamental concepts of metal forming technology nptel. Electromagnetic forming emf is a type of highvelocity, cold forming process for electrically metals, which experiences a rapid growth 1, 2. Also it can be determined that the length of a work piece that can be metal forged by this manufacturing process, is limited by the size of the rolls and the portion of. May 07, 2017 mainly sheet metal process can be divided into three types. Two prominent methods of converting raw material into a product have been metal forming and machining. What is forging process, operation, types, application. Superplastic forming an overview sciencedirect topics. Manufacturing process study notes handwritten free pdf. Subject guide heat treating 3 an intermediate temperature, the host metal rejects the alloying element in the form of a fine, uniformly distributed precipitate in the alloy matrix. Ppt metal forming processes powerpoint presentation. In forming processes, such as forging, the instantaneous flow stress can be found from the flow curve, as the stress required to cause a given strain or deformation.
Plastic properties of metals are used during the process of metal forming. The electromagnetic forming process emf is a highly dynamic process using pulsed mag netic f ields to form metals with high electrical conductivity such as aluminium. More than 90% of smelted metal is processed by different methods of metal forming. The present module describes the salient aspects of forging process. Lecture series on manufacturing processes i by prof. Powder metallurgy pm is a metal working process for forming precision metal components from metal powders.
Even though roll forging uses rolls in order to accomplish the deformation of the material, it is classified as a metal forging process and not a rolling process. Metal forming processes are characteristic in that the metal being processed is plastically deformed to shape it into a desired geometry. We are here to provides you the best study notes from best coaching like made easy, ace academy etc and lecture notes from best institutions like mit open course, iit nptel, crec tirupati, washington, middle east technical university etc. The author has conducted research in metal forming and has taught the subjects of metal forming analysis and metal forming technology to the graduate and undergraduate students of iit bombay and iit delhi for a total period of more than 35 years, during which time, he also guided many ph. Plastics processing plastics can be machined, cast, formed, and joined with relative ease requiring little postprocessing or surfacefinish operations plastics melt or cure at relative low temperatures plastics require less energy to process than metals raw materials most commonly are pellets, powders.
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