Theory: 50 %

Practice: 50 %

Recommended semester: 5

Study mode: full-time

Prerequisites:

Evaluation type: exam

Course category:

Language: english

Responsible instructor: Dr. Béres Gábor József

Instructor(s):

Course objectives:
The aim of the Sheet Metal Forming course is for mechanical engineering students to understand the relationship between the microstructure of metals and mechanical properties, and to acquire knowledge about the sheet metal forming technologies commonly used in practice, their characteristics, applications, as well as the basic knowledge required for related forming and processing technologies.

Course content - lectures:

The material structural and plasticity fundamentals of sheet metal forming: stress, stress state, strain measures, strain state, volume constancy, relationship between stresses and strains, anisotropy. Classification and general characteristics of sheet materials and sheet metal forming technologies. Component manufacturing by blanking, punching. Blanking and punching tools. Strip layout, step-limiting methods, pressure centers. Determination of punching force requirement, utilization of active elements. Bending technology. Bending tools. General aspects of deep drawing. Stress and strain state during bending. Technological design of deep drawing and bending. Design issues of deep drawing tools. Theoretical and practical aspects of achievable draw ratios in a single operation. Classification and structural design of deep drawing tools. Automotive applications: manufacturing of large sheet metal components, vehicle body elements, stretch forming, and forming limit diagrams. Technological tests (Erichsen and Nakajima deep drawing tests, Swift cupping test).

Course content - labs:

Acquired competences:
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.

Skills:

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.

Attitude:

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.

Autonomy and responsibilities:

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.

Additional professional competences:

Requirements, evaluation, grading:
Mid-term study requirements:

Exam requirements:

Study aids, laboratory background:

Compulsory readings:

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.

Recommended readings:

J. Lin: Fundamentals of Material Modelling for Metals Processing Technologies, Imperial College London, 2014.