Course title, code: Metal Forming, GAGEBAN-KEPLEKEN-1
The aim of the Sheet Metal Forming course is for mechanical engineering students to understand the relationship between the microstructure of metals and their mechanical properties, and to gain knowledge about the volume forming/sheet metal forming technologies commonly used in practice, their characteristics, applications, as well as the basic knowledge required for related forming and processing technologies.
Basic knowledge of plasticity. Concept of forming strength and equivalent strain, flow curves. Conditions for the onset of plastic deformation, formability. Work of plastic deformation. Material structural aspects of plastic forming: dislocation theory cold and hot forming, static and dynamic recrystallization. Material models: elastic and plastic properties of materials. Classification of volume-forming technologies. Hot forming: forging, direct and indirect extrusion, and the role of rolling in the production of component blanks. Classification and characteristics of cold volume-forming technologies. Cold extrusion technology. Stress and strain states during cold extrusion, cold extrusion presses and tools. Forming in conical cavity. Rod drawing, reduction. Forward extrusion of solid and hollow bodies. Comparison of forward extrusion of hollow bodies and thinning deep drawing. Design and planning of forward, drawing, and reduction tools. Backward extrusion. Backward extrusion of thick- and thin-walled hollow bodies. Design and planning of backward extrusion tools, preload accommodation. Finite element techniques.
Course content - labs:
Basic knowledge of plasticity. Concept of forming strength and equivalent strain, flow curves. Conditions for the onset of plastic deformation, formability. Work of plastic deformation. Material structural aspects of plastic forming: dislocation theory cold and hot forming, static and dynamic recrystallization. Material models: elastic and plastic properties of materials. Classification of volume-forming technologies. Hot forming: forging, direct and indirect extrusion, and the role of rolling in the production of component blanks. Classification and characteristics of cold volume-forming technologies. Cold extrusion technology. Stress and strain states during cold extrusion, cold extrusion presses and tools. Forming in conical cavity. Rod drawing, reduction. Forward extrusion of solid and hollow bodies. Comparison of forward extrusion of hollow bodies and thinning deep drawing. Design and planning of forward, drawing, and reduction tools. Backward extrusion. Backward extrusion of thick- and thin-walled hollow bodies. Design and planning of backward extrusion tools, preload accommodation. Finite element techniques.
Knowledge:
Comprehensively understands the basic facts, directions, and limits of the technical field. Knows the general and specific mathematical, natural, and social science principles, rules, relationships, and procedures necessary for practicing the technical field. At the applied level, knows the requirements and expectations of work and fire safety, security technology, and occupational health in relation to their field, as well as relevant environmental regulations. Comprehensive understanding of the fundamentals, limits, and requirements of logistical, management, environmental, quality assurance, information technology, legal, and economic areas associated with mechanical engineering.
Capable of identifying routine professional problems, uncovering the theoretical and practical background necessary to solve them, formulating and solving them (with the practical application of standard operations). Able to understand and use characteristic literature, computational, and library resources of their field. Capable of directing and controlling technical manufacturing processes while keeping elements of quality assurance and quality control in mind. Able to diagnose mechanical failures, select corrective operations, and solve repair tasks. Capable of applying and enforcing safety, fire safety, and hygiene rules and regulations during work.
In complex or unexpected decision-making situations, makes decisions taking into full account legal regulations and ethical norms. Possesses appropriate perseverance and monotony tolerance for performing practical activities. Open and receptive to new, modern, and innovative procedures and methods related to ecological management and health awareness. Adheres to and enforces relevant safety, health, environmental, quality assurance, and control requirements during work.
Identifies shortcomings in applied technologies, risks in processes, and initiates measures to reduce them. Keeps track of legal, technical, technological, and administrative changes related to the field. Under the guidance of workplace leaders, directs the work of assigned personnel, supervises the operation of machinery and equipment. Shares experiences with colleagues, thereby assisting in their development. Takes responsibility for technical analyses and proposals formulated based on them.
Mid-term study requirements:
Exam requirements:
T. Altan, A.E. Tekkaya: Fundamentals of Shett Metal Tool Design, ASM Interantional, 2012. K. Lange: Handbook of Metal Forming, Society of Manufacturing Engineers, 1985.
J. Lin: Fundamentals of Material Modelling for Metals Processing Technologies, Imperial College London, 2014.