Sheet metal forming with elastic tools is commonly used in. Self reading for your interestself reading for your interest defects in metal forming processesdefects in metal forming processes and their remedies. Casting process exploit the fluidity of a metal in liquid state as it takes shape and solidifies in a mold. Electrical, electronics and communications engineering. The other forming processes or other manufacturing processes are like casting welding machining all that and there are other varieties. Home forums breezeworks heat treatment pdf nptel tagged. Then the problem is the time required will also be high, then and another problem is the spring back problem. Generally, process improvements are made regularly with new efficiencies embedded within the process. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 7 of. Stress, strain, elasticity and plasticity stress transformation and mohr s circle. Introduction to stretch forming stretch forming is the forming of a sheet blank with a rigidonepiece punch, whereby the blank is rigidly clamped at the edges. Some common metal forming processes are schematically given in fig 1. The fundamental of metal forming theory, the theories of processes of rolling, forging and stamping as well as draw ing and pressing extrusion have been given.
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. Under the action of such forces, the shape and size of metal piece undergo a change. Fundamentals of manufacturing processes 46,101 views. Log in register lost password viewing 1 post of 1 total author posts december 10, 2018 at 7. Metal forming processes are characteristic in that the metal being processed is plastically deformed to shape it into a desired geometry. Coefficients of friction in forming processes are quiet high. Gate 2019 mechanical engineering syllabus contains engineering mechanics, mechanics of materials, theory of machines, vibrations, machine design, fluid mechanics, heattransfer, thermodynamics, engineering materials, casting, forming and joining processes, machining and machine tool operations, metrology and inspection, computer integrated manufacturing, production planning and control. Non traditional manufacturing processes an overview introduction nontraditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be. Nptel mechanical engineering manufacturing processes i. Nptel mechanical engineering forming sheet metal operations.
Many difficult to form materials like titanium and tungsten alloys, can be deformed under high strain rates. In bulk deformation processing methods, the nature of force applied may be compressive. Cutting and forming thin sheets of metal usually performed as cold working sheet metal 0. Casting process exploit the fluidity of a metal in liquid state as it takes shape and. Metal forming and machining processes springerlink. Powder metallurgy pm is a metal working process for forming precision metal components from metal powders. By mechanical working processes, the given shape and size of a machine part can be achieved with great economy in material and time.
Machining is the process of removing the material in the form of chips by means of a wedge shaped tool. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. Fundamentals of forming fundamental concepts of metal forming. Metal in powder form is costlier than in solid form. The temperature of work is increases due to adiabatic heating. This lecture describes the fundamentals of rolling process including working principle, calculation of various rolling parameters rolling force, power consumption, torque etc. Metal forming processes full notes ebook free download pdf. Advances in sheet metal forming technologies 65 special presses to stand for high pressures up to 80 mpa in the pressure chamber. The consumable electrodes will be changed periodically as it is consumed for each welding trials.
Rolling, forging, extrusion and drawing are bulk forming processes. The advantages of metal forming processes include no wastage of the raw material, better mechanical properties of the product and faster production rate. Choose your course from different course categories. Moving on, let us see some new processes like high energy rate forming process, then rapid prototyping process and microwave material processing techniques.
Introduction to metal forming technology classification of metal working processes behavior of materials failure of materials concept of stress and strain. The electrode is consumed by the arc during the welding process and added to the weld joint as filler metal. This is very much associated with all the conventional forming, most of the conventional forming processes applied to sheet metal forming. Present in rod or wire form with 200 to 450 mm length and less than 10 mm diameter. These are casting, machining, joining welding, mechanical fastners, epoxy, etc. Thermoforming is the forming of heated plastic on a mold to create a desired shape. Injection molding complex shapes of various sizes, eliminating assembly. If coefficient of friction becomes very high it leads to a situation called sticking friction. Thermoforming, vacuum forming and pressure forming are considered thermoforming processes.
Forming metal forming is the approach of creating the metallic components by deforming the metal but not by removing, cutting, shredding or breaking any part. Recent advances in metal forming processes authorstream presentation. Fundamental concepts of metal forming technology nptel. The forming processes are affected by the rates of strain used. What is the procedure of registration for nptel free. Manufacturing processes i nptel online videos, courses.
Metal forming processes full notes ebook free download pdf practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. Sheet metal forming massachusetts institute of technology. The rolls work together to form the desired crosssection. Forming forming operations change the geometry of the starting material without cutting it.
Ppt metal forming processes powerpoint presentation. Comparison of metal forming processescomparison of metal forming processes 34. Lecture series on manufacturing processes i by prof. Why powder metallurgy is important pm parts can be mass produced to net shape or near net shape, eliminating or reducing the need for subsequent machining pm process wastes very little material about 97% of the starting powders are converted to product pm parts can be made with a specified level of porosity, to produce porous metal parts. Manufacturing processes i nptel online videos, courses iit video lectures. 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. In this process, an impulse current is employed to. Bending, spinning, drawing, and stretching are a few important metal forming process in manufacturing. Metal forming processes indian institute of technology. Improved lubrication if lubricating film is maintained. Go to national programme on technology enhanced learning step 2. The blank can be clamped between rigid tools,corresponding to the upper and lower drawing frames of the conventional tools, or be clamped in.
Metal casting is a labour intensive process automation. Mechanical engineering manufacturing processes i nptel. Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section. Electroforming definition electroforming is a metal forming process that forms thin parts through the electroplating process. Electromagnetic forming emf is a type of highvelocity, cold forming process for electrically metals, which experiences a rapid growth 1, 2. There are four basic production processes for producing desired shape of a product. Sharma, department of mechanical engineering, iit roorkee. Often confused with injection molding and rotationalmolding, thermoforming processes are unique and have distinct differences for a variety of. A poorly designed process results in overuse of manufacturing resources men and machines. Metal forming metal forming is a general term for a large group, that includes a wide variety of manufacturing processes.
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