Course title, code: Introduction to the Metal Forming, GAGEBAN-BEVAKEPL-1
The aim of the Introduction to Plastic Deformation course is to familiarize mechanical engineering students with the relationship between the microstructure of metals and their mechanical properties, as well as to provide practical knowledge about material forming technologies, their characteristics, applications, and fundamental knowledge necessary for related plastic deformation and processing technologies.
The course material of the lectures covers the following topics: 1. Fundamentals of material structure and plasticity in Plastic Deformation: stress, stress state, deformation measures, deformation state, volume constancy. 2. Classification and general characterization of sheet metals and sheet forming technologies. 3. Component manufacturing by cutting and punching. Punching tools. Strip layout, step-limiting methods, pressure center, determination of cutting and punching force requirements, utilization of active elements. 4. Special material separation and sheet component manufacturing processes. 5. Economic aspects of sheet component manufacturing. 6. Bending technology. Bending tools. 7. General aspects of deep drawing. Stress and deformation state. Technological calculations of deep drawing, design issues of deep drawing tools. Manufacturing of large sheet components, vehicle body manufacturing, stretching drawing, forming limit diagrams. 8. Special sheet forming processes (High-speed forming, hydro-mechanical deep drawing, etc.). 9. Classification of volume forming technologies. Hot forming: forging, direct or indirect pressing, and rolling in the production of semi-finished parts. 10. Cold volume forming: Cold upsetting, forming in a tapered cavity: drawing and reducing. Flow forming of solid and hollow bodies. Backward extrusion of thick-walled hollow bodies. Flow tools and their pre-stressed clamping. (Gábor Béres) The practical sessions cover: 1. Occupational safety training, structure of punching tools. 2. General structure and operation of press machines. 3. Flow curve acquisition methods. Measurement protocol. 4. The role of friction in plastic deformation, ring compression test. Measurement protocol. 5. Assignment: understanding the complex 3D sheet component manufacturing module, planning the production steps. 6. Layout preparation, determination of layout characteristics, preparation of cutting, and punching technological plans. 7. Design and drawing steps of cutting and punching tools, design theory, design approach. 8. Design and drawing steps of cutting and punching tools, design theory, design approach. 9. Design steps of 3D sheet component manufacturing technologies, design theory: bendability, springback, deep-drawing ability, determination of drawing operations. Submission of cutting and punching tool design task. 10. Finite element simulation techniques: cold upsetting, ring compression. 11. Finite element simulation techniques: drawing, reducing, forward extrusion. 12. Methodology for solving plastic deformation tasks: screw manufacturing. 13. Factory visit: MBMH Ltd. Pressing Plant.
Course content - labs:
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:
vizsgajegy
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.