Lovely Professional University, Punjab

Course Code Course Title Course Planner Lectures Tutorials Practicals Credits

MEC525 MECHANICS OF METAL FORMING 16845::Pankaj Kumar 3.0 0.0 0.0 3.0

Course Orientation 1 :DISCIPLINE KNOWLEDGE, 5 :PLACEMENT EXAMINATION, 7 :COMPETITIVE EXAMINATION(Higer Education), 8 :COMPETITIVE EXAMINATION(Civil Services)

TextBooks

Sr No Title Author Edition Year Publisher Name

T-1 MECHANICAL METALLURGY GEORGE E. DIETER 3rd 2013 MCGRAW HILL EDUCATION

Reference Books

Sr No Title Author Edition Year Publisher Name

R-1 TECHNOLOGY OF METAL FORMING PROCESSES

SURENDER KUMAR 1st PRENTICE HALL

R-2 A textbook of Production Engineering P.C. Sharma 11th 1982 S. CHAND & COMPANY

Relevant Websites

Sr No Web address (only if relevant to the course) Salient Features

RW-1 http://thelibraryofmanufacturing.com/forming_basics.html Information and description related to Forming

RW-2 http://www.efunda.com/formulae/solid_mechanics/mat_mechanics/calc_principal_stres s.cfm

Stress calculator

RW-3 http://www.google.co.in/url? sa=t&rct=j&q=&esrc=s&source=web&cd=2&cad=rja&ved=0CDUQFjAB&url=http %3A%2F%2Facademic.uprm.edu%2Fpcaceres%2FCourses%2FMMII%2FIMoM- 5A.pdf&ei=kWeEUsu1I4nGrAeRpIHoAw&usg=AFQjCNHo0WGreYWWXVAGAgOx- PkhkQ4Yg&sig2=-2SOFiKHB7XaBE3R4hinjQ&bvm=bv.56343320,d.bmk

Principal stresses and calculation

Detailed Plan For Lectures

LTP week distribution: (LTP Weeks)

Weeks before MTE 7

Weeks After MTE 7

Spill Over 7

Week Number

Lecture Number

Broad Topic(Sub Topic) Chapters/Sections of Text/reference books

Other Readings,Relevant Websites, Audio Visual Aids, software and Virtual Labs

Lecture Description Learning Outcomes Pedagogical ToolDemonstration/ Case Study / Images / animation / ppt etc. Planned

Live Examples

Week 1 Lecture 1 Introduction and state of stresses(Strength of material-basic assumptions)

Lecture Zero Knowledge of basics of metal forming techniques and basic overview of course

PPT and Animations

auto mobile components made from metal forming processes like crankshaft, piston

Lecture 2 Introduction and state of stresses(Elastic and plastic behavior of metals)

T-1:1 Behavior of materials inelastic and plastic region

Learning of materialcharacteristics

PPT and Discussion

Stress-Strain diagram for ductile material

Introduction and state of stresses(Average stress and strain)

T-1:1 Average stress andstrain

Learning of stressand strain concepts

Discussion

Lecture 3 Introduction and state of stresses(Tensile deformation of ductile metals)

T-1:1 Tensile deformation of metals

Stress strain diagram PPT Tensile test UTM

Introduction and state of stresses(Ductile vs Brittle behavior)

T-1:1 RW-1 Ductile vs Brittlebehavior

Behavior of metals inductile and brittleregion

PPT Tensile test UTM

Week 2 Lecture 4 Introduction and state of stresses(Cold,hot and warm forming and types of stresses)

R-1:1 RW-1 Cold working and Hotworking

Learning ofrecrystallisationtemperature. Change in grain structure with temperature

PPT and Discussion

Martensite in TTT diagram

Lecture 5 Introduction and state of stresses(Experiments and bulk deformation processes)

T-1:18R-1:1

RW-1 Different types ofdeformation processes like Extrusion, Drawingand rolling

Working of metaldeforming processes.

Figures of differentmetal deformationprocesses

Extruded products like hollow pipes

Introduction and state of stresses(Temperature and crack formation)

R-1:1 RW-1 Relation betweentemperature andcracking in deformationprocesses.

Effect of temperatureon cracking indeformationprocesses

Figures of differentmetal deformationprocesses

Lecture 6 Introduction and state of stresses(Components and principle stresses)

R-1:2 RW-1 Different components of stresses.

Basic understanding ofdifferent components ofstresses.

Rectangular blockrepresentingstresses

Week 3 Lecture 7 Stress and strain relationships and Elastic behaviours(Description of stress at a point)

T-1:2 Component of stresses Different type ofstresses (normal andshear stresses)

Figure of stressesacting cube.

Week 3 Lecture 8 Stress and strain relationships and Elastic behaviours(state of stress in two and three dimensions)

T-1:2 Plane stresses in twoand three dimensions

Calculation ofstresses in two and threedimensions

Figure of stresseson oblique plane

Lecture 9 Stress and strain relationships and Elastic behaviours(Mohr's circle of stress in two dimension)

T-1:2R-1:2

Formation of mohr'scircle with numericals

Calculation ofstresses with the help of mohr's circle. Numerical problems

Figure and Discussion

Week 4 Lecture 10 Stress and strain relationships and Elastic behaviours(Hydrostatics and Deviator components of stress)

T-1:2 RW-3 Role of Hydrostatics andDeviator components ofstress

Effect of stresscomponents

Sketches and Discussion

Stress and strain relationships and Elastic behaviours(Elastic stress strain relations)

T-1:2 RW-1 Stress strain relation Knowledge aboutstress strainrelationship

Hooke's law Digram between stress strain

Lecture 11 Stress and strain relationships and Elastic behaviours(Calculations of stresses from elastic strains)

T-1:2 RW-2 Numerical problems on Stress strain relation

Knowledge aboutstress strainrelationship

Numerical

Lecture 12 Test1

Week 5 Lecture 13 Yield criteria and flow rules(Introduction)

T-1:3 RW-1 Introduction abouttheory of plasticity

Introduction abouttheory of plasticity

Figure of Stress straincurves of differentmaterials

Tensile test onUTM

Yield criteria and flow rules(The flow curve)

T-1:3 Description of flowcurve

Knowledge aboutflow curve

Idealized flowcurve

Tensile test onUTM

Lecture 14 Yield criteria and flow rules(True stress and true strain)

T-1:3 Relation between true stress and true strain

Knowledge aboutstress-strain equations

Discussion Equations ofstress strain relation

Lecture 15 Yield criteria and flow rules(Yield criteria of ductile metals)

T-1:3 Von Mises orDistortion energyCriterion. Tresca Yield criteria

Calculation of stresses for ductilematerials

DiscussionEquations of VonMises and tresca

Week 6 Lecture 16 Yield criteria and flow rules(Combined stress test)

T-1:3 Combined stress test Combination ofdifferent stresses and yield criteria

Discussion Torsion test

Yield criteria and flow rules(Octahedral shear stress and shear strain)

T-1:3 Shear stress and shear strain in Octahedral condition

Knowledge about the calculation of stress andstrain

Demonstration byFaculty

Lecture 17 Yield criteria and flow rules(Invariants of stress and strain)

T-1:3 Invariants of stress and strain

Invariants of stressand strain

Discussion

Yield criteria and flow rules(Levy Mises equation)

T-1:3 Plastic stress-strainrelation

Levy Mises equation Discussion anddemonstration byfaculty

Week 6 Lecture 18 Yield criteria and flow rules(Prandtl Reuss equation)

T-1:3 Plastic stress-strainrelation

Prandtl Reussequation

Discussion anddemonstration byfaculty

Week 7 Lecture 19 Yield criteria and flow rules(Slip line field theory)

T-1:3 Two Dimensionalplastic flow Slip linefield theory

Methods ofdevelopingplastic constraint

Sketches andDiscussion

SPILL OVERWeek 7 Lecture 20 Spill Over

Lecture 21 Spill Over

MID-TERMWeek 8 Lecture 22 Forging and rolling of

metals(Classification of forging process)

T-1:16 Different types offorging processes

Uses of forgingprocesses

Figure of differenttypes of forgingprocesses

Crankshafts

Forging and rolling of metals(Equipments)

T-1:16 Different types offorging equipments

Uses of forgingequipments

Figure of differenttypes of forgingequipments

Hydraulic and mechanical forging press

Lecture 23 Forging and rolling of metals(Forging plain strain)

T-1:16 Forging plain strain Calculation of forcesin forging

Demonstration byfaculty

Forging and rolling of metals(Open die and close die forging)

T-1:16 Description of open and closed die forging.

Knowledge aboutdifferent types offorging dies

Figures of openand closed die forging.

Engine blocks

Lecture 24 Forging and rolling of metals(Analysis of Closed die forging by slab method)

R-2:13 Analysis of open dieforging with stickingfriction

Numerical problemfor solving pressuredistribution that isfriction hill

Demonstration byfaculty

Week 9 Lecture 25 Forging and rolling of metals(Calculation of Forging loads in closed die forging)

T-1:16 Calculation of Forgingloads in closed-dieforging

Numerical Calculation of loads

Numerical

Lecture 26 Forging and rolling of metals(Hot rolling and cold rolling)

T-1:17 RW-1 Hot and cold rolling Different types ofrolling

Figures of Rollingmill

Thin sheets

Forging and rolling of metals(Rolling of bar and shapes)

T-1:17 RW-1 Methods of rolling Different types ofrolling

Figures of Rollingmill

Lecture 27 Forging and rolling of metals(Forces and geometrical relationship in rolling)

R-2:13 Analysis of Rolling Derivation of rollingload with concepts ofneutral point

Demonstration byfaculty

Week 10 Lecture 28 Forging and rolling of metals(Calculation of rolling load)

T-1:17 Calculation of forgingload

Derivation Demonstration byfaculty

Forging and rolling of metals(Numerical Problems)

T-1:17 Numerical problem on rolling

Numerical problem Demonstration byfaculty

Lecture 29 Test2

Week 10 Lecture 30 Extrusion and Drawing(Classification of Extrusion process)

T-1:18 RW-1 Different types ofextrusion and drawing processes

Uses of extrusionprocesses

Figure of differenttypes of forgingprocesses

Tooth-paste

Week 11 Lecture 31 Extrusion and Drawing(Analysis of extrusion process)

T-1:18 Analysis of extrusionprocess

Knowledge aboutdifferent forces inextrusion

Figure of stress strain distribution in partial tube

Lecture 32 Extrusion and Drawing(Defects in extrusion)

T-1:18 Different types oflubrication and defects inextrusion processes

Knowledge aboutlubrication anddefects in extrusion processes

PPT Wrinkles and distortion defect

Extrusion and Drawing(Hydrostatic extrusion)

T-1:18 Use of hydro pressure inextrusion processes

Role of hydrostaticpressure in extrusion

PPT

Lecture 33 Extrusion and Drawing(Rod and wire drawing)

T-1:19 Different types ofdrawing processes

Use and working ofdrawing processequipments

Figures of differentdrawing processesand PPT

Extrusion and Drawing(Analysis of wire drawing)

T-1:19 Analysis of forces acting process

Knowledge relatedforces in wire drawing

Faculty demonstration byfaculty

Week 12 Lecture 34 Extrusion and Drawing(Tube drawing process)

T-1:19 Types of tube drawing processes

Knowledge abouttube drawing

PPT Wires

Extrusion and Drawing(Analysis of tube drawing)

T-1:19 Analysis of forces acting during process

Knowledge relatedforces in tube drawing

Facultydemonstration

Lecture 35 Extrusion and Drawing(Numerical problems)

T-1:19 RW-1 Numerical problem on extrusion and drawing

Problem solution Numerical

Lecture 36 Test3

Week 13 Lecture 37 Sheet metal Forming and Lubrication mechanisms(Forming methods)

T-1:20 RW-1 Introduction andmethods of sheetforming processes

Different types ofsheet formingprocesses

Figures of differentsheet formingprocesses

Perforation

Sheet metal Forming and Lubrication mechanisms(Shearing and Blanking)

T-1:20 RW-1 Introduction andmethods of shearing andblanking processes

Different types ofshearing and blanking

processes

Figures of differentshearing andblankingprocesses

Washers

Sheet metal Forming and Lubrication mechanisms(Bending)

T-1:20 RW-1 Definition of terms used in bending

Springback inbending

Different types ofbending processes

Lecture 38 Sheet metal Forming and Lubrication mechanisms(Stretch forming)

T-1:20 RW-1 Stretch formingoperation

Variation of necking Figures of stretchingprocesses

Sheet metal Forming and Lubrication mechanisms(Deep drawing)

T-1:20 RW-1 Description of Deepdrawing

Analysis of deep drawing

Figures of differentdrawing processes

Bottles and deep cup

Sheet metal Forming and Lubrication mechanisms(Forming limit criteria)

T-1:20 RW-1 Description forminglimit

Analysis of forminglimit

Forming limit diagram

Week 13 Lecture 39 Sheet metal Forming and Lubrication mechanisms(Lubrication principle and mechanism)

R-1:7 Lubrication principleand mechanism

Knowledge aboutlubrication mechanism

Figure of threeregimes of lubrication

Sheet metal Forming and Lubrication mechanisms(Lubrication need and their components and cost selection)

R-1:7 Need of lubrication inindustries

Knowledge aboutcosts of lubrication

Differentcomponents of costs in lubrication

Week 14 Lecture 40 Sheet metal Forming and Lubrication mechanisms(Chemical characteristics and solid lubrication)

R-1:7 Chemical characteristicsvalues and categories ofsolid lubrication

Types of solidlubrication

Demonstration byFaculty

Grease

Sheet metal Forming and Lubrication mechanisms(classification of lubricants and use in forming process)

R-1:7 classification oflubricants

Use of lubrication informing process

Demonstration byFaculty

SPILL OVERWeek 14 Lecture 41 Spill Over

Lecture 42 Spill Over

Week 15 Lecture 43 Spill Over

Lecture 44 Spill Over

Lecture 45 Spill Over

Scheme for CA:Component Frequency Out Of Each Marks Total Marks

Test 2 3 10 20

Total :- 10 20

Details of Academic Task(s)

AT No. Objective Topic of the Academic Task Nature of Academic Task(group/individuals/field

work

Evaluation Mode Allottment / submission Week

Test1 To check student's ability to understand subject matter through written test

Strength of material-basic assumptions, Elastic and plastic behavior of metals, Average stress and strain, Tensile deformation of ductile metals, Ductile vs Brittle behavior, Cold,hot and warm forming and types of stresses, Components and principle stresses, Experiments and bulk deformation processes, Temperature andcrack formation. Description of stress at a point, state of stress in two and three dimensions, Stress tensor, Mohr's circle of stress- two dimension, Hydrostatics and Deviator components of stress, Elastic stressstrain relations, Calculations of stresses from elastic strains, Strain energy

Individual Answers should be to the point and problems should be solved step wise.

3 / 4

Test2 To check the understanding of students about the topics done in class

Introduction, The flow curve, True stress and true strain, Yield criteria of ductile metals, Combined stress test, Yield locus, Anistropy in yielding, Yield surface and normality, Octahedral shear stress and shear strain, Invariants of stress and strain, LevyMises equation, Prandtl Reuss equation, Slip line field theory. Classification of forging process, Equipments, Forging plain strain, Open die and close die forging, Analysis of Closed die forging by slab method, Calculation of Forging loads in closed die forging, Hot rolling and cold rolling, Rolling of bar and shapes, Forces and geometrical relationship in rolling, Calculation of rolling load, Numerical Problems

Individual Answers should be to the point and problems should be solved step wise.

9 / 10

Test3 To check student's ability to understand subject matter through written test

Classification of Extrusion process, Deformation lubrication and Defects in extrusion, Analysis of extrusion process, Hydrostatic extrusion, Rod and wire drawing, Analysis of wire drawing, Tube drawing process, Analysis of tube drawing

Individual To check the understanding of students about the topics done in class

11 / 12