Theory: 50 %

Practice: 50 %

Recommended semester: 5

Study mode: full-time

Prerequisites: Vehicle materials and technologies

Evaluation type: exam

Course category:

Language: english

Responsible instructor: Dr. Béres Gábor József

Instructor(s): Dr. Béres Gábor József, Borbély Richárd, Kölüs Martin László, - nincs

Course objectives:
Vehicle engineer students can get to know the relationships between the microstructure and mechanical properties of the metallic materials. The course introduces the basics of the metal forming technologies, such as the characteristics and application of each forming operations. The fundamental theory of plasticity is also presented.

Course content - lectures:

Fundamentals of the plasticity and metallography of metallic materials. The phenomenon and concept of stresses and strains as well stress and strain states, volume constancy. Sheet metal forming technologies, clustering of the technologies. Manufacturing by punching and blanking. Tool sets for punching and blanking: layout, feeding, force requirement, die loads. Special material separation operations. Technology and tools of bending. Geometry defects, springback. Fundamentals of deep-drawing. Stress and strain states at deep-drawing. Construction of deep-drawing dies and process planning. Manufacturing of body panels, stretch forming and forming limit curves. Special sheet forming operations (hydroforming, high energy-rate forming, forming by rubber pads). Fundamentals and clustering of bulk forming technologies. Hot bulk forming technologies: forging and rolling. Cold bulk forming operations: upsetting, extrusion and drawing.

Course content - labs:

Structure and mechanism of press machines. Editing flow curve in the practice. Determination of friction coefficient in the practice. Blank layout design in practice: calculation of blank properties, technological design of blanking and punching process. Engineering design of blanking-punching tool: calculation of material yield and forces, as well as machining tolerances, mechanical inspection of active elements, engineering design of active elements, engineering design of the die set. Process design for bending and deep-darwing of thin sheets. Process design of cold upsetting. Process design of cold extrusion.

Acquired competences:
Knowledge:

Skills:

Attitude:

Autonomy and responsibilities:

Additional professional competences:

Comprehensive knowledge of the basic facts, directions and boundaries of the subject area of the technical field. He / her is aware of the legal, economic, safety, social, health and environmental consequences of his work and decisions. It makes independent, professionally based decisions even in unexpected decision situations. In the course of his professional duties, he also cooperates responsibly with qualified professionals in other (primary economic and legal) fields.

Requirements, evaluation, grading:
Mid-term study requirements:
Semester requirements: - Preparation of test report of the flow curve definition. - Preparation of the design of the punch die set. - mid-semester written test: min. 50%.
Exam requirements:

Written and oral final exam: min. 50%.

Generative AI usage:

1st position: The use of GAI tools is not permitted when solving tasks. This means that GAI tools cannot be used when creating or solving formative or summative assessment elements, and the use of generative AI constitutes academic misconduct. The use of AI tools for language and spelling checking is not subject to the complete ban under the 1st position.

Study aids, laboratory background:

Metal forming laboratory and workshop.

Compulsory readings:

ASM Handbook Volume 14A: Metalworking: Bulk Forming, AMS International 2021; ASM Handbook Volume 14B: Metalworking: Sheet Forming, AMS International 2021.

Recommended readings:

Taylan Altan, A. Erman Tekkaya: Fundamentals of Sheet Metal Forming, ASM International 2012; Kurt Lange: Handbook of metal forming, SME, 1985.