Forming Process also known as Metal Forming is a large set of manufacturing processes by which raw material is converted into a product. In this process, we apply stresses like tension, compression, shear, etc. to deformed the raw material. The example of forming processes are sheet metal manufacturing, forging, rolling, extrusion, wire drawing, and so on

Metal forming processes are an essential part of our society, and without them, our society would come to a grinding halt.

The products and components created by the different metal shaping techniques are used in creating everything from scaffolding and heavy machinery to designing and creating microprocessors and artificial intelligence.

When it comes to metal forming, there are several processes to choose from, with each offering its own list of benefits and detriments, each suited to certain applications, and each suited for different types of metal.

COURSE OUTLINE

Introduction to the Fundamentals of Metal Forming Processes

Fundamentals of metal forming
Types of deformation processes of metal
Bulk deformation (Rolling, Forging, Extrusion, Wire Drawing)
Sheet metal working
Stress-Strain Curve
Derivation of the relation between stress and strain
Flow stress and Average flow stress
The temperature in metal forming (Cold working and Hot-working)
Recrystallization
Iso thermal forming (recovery and Grain growth)
Strain rate Sensitivity

Rolling Process

Introduction of rolling
Shapes used for rolling
Types of rolling
Working on the rolling process
Analysis of the rolling
Rolling mills
No-Slip Point for rolling
Flatness control and rolling defect
Numerical Problems related to the rolling process

Forging Process

Introduction to forging
Classification of forging
Types of forging
Analysis of the forging
Barreling effect in forging
Open Die forging and its practices
Impression Die forging and its practices
Advantages and Limitations of Impression Die forging
Fleshless forging
Forging Press and Forging Hammers
Numerical Problems related to the forging process

Extrusion Process

Introduction to the extrusion process
Classification of extrusion
Direct and Indirect extrusion
Hot and Cold extrusion
Direct and Continuous extrusion
Analysis of the extrusion process
Effect of friction on extrusion
Extrusion Dies and Orifice
Extrusion press and other extrusion processes
Numerical Problems related to the extrusion process

Drawing Process

Introduction to Drawing
Difference between drawing and wire drawing
Bar Drawing
Wire Drawing
Features of Draw Die
Preparation of the work
Analysis of the drawing process

Sheet Metal Forming Processes

Sheet metal Cutting

Introduction to sheet metal cutting process
Characteristics of Edges
Types of sheet metal cutting
Shearing
Blanking and Punching
Clearance in Sheet metal cutting
Analysis of sheet metal cutting processes
Numerical Problems related to the sheet metal cutting process

Sheet Metal Bending

Introduction of sheet metal bending process
Types of sheet metal bending
Analysis of the sheet metal bending process
Numerical Problems related to the sheet metal bending process
Spring Back

Sheet Metal Drawing

Introduction to the drawing process
Mechanics of drawing
Stages of deformation
Analysis of the drawing process
Tests of Drawing Feasibility
Blank force and blank size determination
Numerical Problems related to the drawing process

Redrawing, Reverse Drawing and Drawing without Blank holder

Other drawing processes (Redrawing, Reverse Drawing and Drawing without Blank holder)
Defects in Drawing
The operation performed with metal tooling
Ironing
Coining & Embossing
Lancing & Twisting
The operation performed with flexible Rubber tooling
Guerin and Hydroforming process
Numerical Problems related to the other drawing processes