One is bulk forming and the other is sheet metal forming. What are the requirements for superplastic forming. In sheet metal forming thickness variations are not desirable. Sheet metal forming involves forming and cutting operations performed on metal sheets, strips, and coils. Working upon sheets, plates and strips mainly constitutes sheet forming. Sheet metal operations other sheet metal forming processes nptel. It is also referred to a complete tool consists of a pair of mating members for producing work in a press. Forming nptel web course free ebook download as pdf file. Sheet metal forming massachusetts institute of technology. In most numerical analysis of sheet metal forming processes, the yield surface is assumed to possess a pointsymmetry with respect to its centre, meaning that a stress state and its reverse state. Sheet metal operations i lecture 38 sheet metal operations ii lecture 39 powder metallurgy forming i lecture 40 powder metallurgy forming ii. Mechanical engineering manufacturing processes i nptel. Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing.
In low carbon steel sheet metal, the minimum radius of a bend should be one. Design for manufacturability sheet metal guidelines. Metal forming processes full notes ebook free download pdf. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 1 of sheet metal operations other sheet metal forming processes r. Some of the original topics have been omitted or given in an abbreviated form in appendices. Reprint with revisions and sheet metal forming processes. Plastic properties of metals are used during the process of metal forming. This lecture describes the fundamentals of sheet metal operations including working principle, mechanisms involved and various processes etc.
Sheetmetal forming includes cutting and forming operations performed on relatively thin sheet of metal typical sheet metal thicknesses. Nptel provides elearning through online web and video courses various streams. Sheet metal forming represents an extensive research area involving numerous topics such as finite element techniques and modeling, material models, material characterization, formability. Sheet metal forming simulation using finite elastoplasticity with mixed isotropickinematic hardening. Nptel mechanical engineering forming sheet metal operations other sheet. So, in sheet metal forming, the shape is produced from a flat blank by stretching and shrinking the dimensions of all its volume elements in three mutually. Chandramouli associate deanresearch sastra university, thanjavur6 401.
Progress in blankholder systems in the pulsating blankholder system the blankholder is subjected to a vibratory pulsating force. Metal casting processes indian institute of technology. Sheet steel is forced into a female cavity by water under pressure from a pump or by press action sheet steel is deformed by a male punch, which acts against the fluid under pressure. Google books result metal forming processes and analysis by b.
Introduction cutting and forming thin sheets of metal usually performed as cold working sheet metal. Pdf in the present study, the survey of research work on finite element analysis of metal forming processes has been carried out. Metal forming processes indian institute of technology. Final shape is obtained by applying tensile, shear or combination of forces and stretching or shrinking the sheet metal. This lecture describes the fundamentals of sheet metal operations including working principle, mechanisms involved and. Manufacturing processes i nptel online videos, courses.
This lecture describes the fundamentals of rolling process including working principle, calculation of various rolling parameters rolling force, power consumption, torque etc. Group from which i have learned much about sheet metal forming. Difference between bulk deformation and sheet metal forming. Size and weight of the product is not a limitation for the casting process. Mechanics of sheet metal forming college of engineering. In recent years, enormous progress has been made in the analysis of forming of complex shapes using. Mainly sheet metal process can be divided into three types. Nptel course on manufacturing processes i, pradeep kumar et al. Sheet metal forming produces parts having large surface area to thickness ratio. Finite element simulation of sheet metal forming processes. The first one is sheet metal cutting, second one is sheet metal bending or forming and the last one is known as deep drawing.
The grob cold rolling process is a non destructive not cutting of natural material grain flow, chipless, high quality and very fast forming process for splines on round solid or sheet metal. Bending straining of a metal sheet to form an angle bend. A sheet formed part is usually obtained through a number of operation phases final surface intermediate surface. Pdf finite element simulation of sheet metal forming.
Comparison of metal forming processescomparison of metal forming processes 34. Sheet metal operations cutting and related processes. Classification of basic sheet forming processes bending deep drawing shearing. Design for manufacturability sheet metal guidelines bends for the ease of manufacturing, multiple bends on the same plane should occur in the same direction. Sheet metal forming is widely used for producing wide range of products starting from household vessels to aerospace parts, to automobile or aircraft bodies. Advances in sheet metal forming technologies 65 special presses to stand for high pressures up to 80 mpa in the pressure chamber. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of. Sheet metal operations are mostly carried out in presses hydraulic or pneumatic. More than 90% of smelted metal is processed by different methods of metal forming. Materials which do not become brittle at higher strain rates alone can be explosive formed. Self reading for your interestself reading for your interest defects in metal forming processesdefects in metal forming. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal. Metal forming is the main method of making metal products and semifinished products.
Avoid large sheet metal parts with small bent flanges. Lecture series on manufacturing processes i by prof. Drawing forming a sheet into a hollow or concave shape. Sheet metal working welcome back under the design for manufacturing topic, injection moulding was discussed.
Finite element formulation for the simulation of hot sheet metal forming processesj somnath ghosh and noboru kikuchi department of mechanical engineering and applied. Sheet metalworkingforming on metal sheets, strips, and coils. The couple of other things that i will discuss part of the design for. Forming and 39 welding by p n rao 40 february 6, 2012 step 4. Cold forming of sheet metal parts ernst grob ag youtube. Particular thanks are given to alejandro graf of alcan, robert wagoner of the ohio state university, john duncan of the university. The key difference between bulk deformation and sheet metal forming is that in bulk deformation, the work parts have a low area to volume ratio whereas, in sheet metal forming, the area. The surface areatovolume ratio of the starting metal is relatively high. Various metal forming techniques and their analysis, viz. Sheet metal operations other sheet metal forming processes. Fundamental concepts of metal forming technology nptel.
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