This lecture describes the fundamentals of rolling process including working principle, calculation of various rolling parameters rolling force, power consumption, torque etc. Nptel provides elearning through online web and video courses. It encompasses conventional pressandsinter technology, metal injection molding, isostatic pressing, metal additive manufacturing metal 3d printing, and powder forging. Nptel provides elearning through online web and video courses various streams. Forging process analysis and preform design by harshil parikh, bhavin mehta, jay gunasekera department of mechanical engineering ohio university, athens, ohio 45701 rob mayer, president queen city forging company, cincinnati, ohio 45226 abstract the purpose of this paper is to optimize the forging process and reduce the required force.
Unit 4 metal coating processes metal coating processes structure 4. Pdf designing, manufacturing and processing of tailored. Joining of materials joining includes welding, brazing, soldering, adhesive bonding of materials. The overall investment of underground machine hall is less than those of the superstructure of a surface power house of similar dimensions. Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. Syllabus course contents nonferrous extractive metallurgy. Bhattacharjee, department of civil engineering, iit delhi. Powder metallurgy is a metal forming process performed by heating compacted metal powders to just below their melting points. Advanced machining processes nptel online videos, courses. Working principle of hot dipping is forming transition layers of varying alloy compositions. Content total hrs % weightage 1 basics of metal forming mohrs circle isotropic elasticity yield theories plastic stress strain relationship plastic work the principle of normality incremental plastic strain 08 22. Manufacturing process ii fundamentals of metal forming 1 introduction metal forming includes a large group of manufacturing processes in which plastic deformation is used to change the shape of metal workpieces.
Coefficients of friction in forming processes are quiet high. Processing of non metals online course video lectures by. Ghosh,department of metallurgy and material science,iit kharagpur. Epub, pdf, and html and on every physical printed page the following attribution. Faculty of engineering and architecture m e c h a n i c a l e n g i n e e r i n g d e p a r t m e n t mech521 manufacturing processes ii catalog description. Email print pdf such as ocean engineering, biotechnology, mining and metallurgy. Apr 26, 20 one of the most important manufacturing processes, metal forming is essential for engineers working in the manufacturing and related sectors. Sharma, department of mechanical engineering, iit roorkee. Which videos of nptel are a must watchbest for mechanical. Lecture notes design and manufacturing ii mechanical. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses.
It is one of the best ways to prepare for competitive exams and also to clear your basics which is important for clearing interviews, during job, further studies etc. During the stable stage of roll forming process, the rolling force fluctuation in each pass is related to the change of forming angle in that pass. An elastic deformation disappears when the load is removed. All aspects of mechanical, electrochemical and thermal processes are comprehensively covered. Metal forming processes full notes ebook free download pdf. Strength of materials nptel online videos, courses iit. Advanced welding,casting, forming processes pdf by. Metal in powder form is costlier than in solid form. High velocity forming of metals and high energy rate forming. The sequences involved in investment casting are shown in figure 11. This book covers fundamental aspects and recent technological developments in the area. Unit 4 metal coating processes metal coating processes. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 7 of. Wolfram volk, pierre charvet bmw ag, munich, germany summary.
The conventional hydroelectric power stations are usually located overground at the foot of a dam or a hill slope on the banks of a river. We have over 14 different end forming machines that can produce almost any shape from simplistic to extreme. The associated procedure may involve several steps, where americium is first. No part of this work may be reproduced or transmitted in any form or by any means, elec tronic or. Sheet metalworking bending operations deep or cup drawing shearing processes bulk deformation processes a forging b extrusion and c wire and bar drawing and d rolling. Metal forming processes indian institute of technology. Load estimation for bulk forging, rolling, extrusion. The course contents and videos uploaded are free to download for all more detailed. At ambient conditions, americium is present in its most stable.
Some common metal forming processes are schematically given in fig 1. It is also the pass that most probably causes quality issues to the final product. Designing, manufacturing and processing of tailored blanks in a sheetbulk metal forming process article pdf available december 2017 with 337 reads how we measure reads. Nowadays the engineering and planning process in sheet metal forming is fundamentally supported by cad and cae systems. This, the most common structural form of the element allotrope, is about as hard and brittle. In this process, a deuteron hitting uranium238 produces two neutrons and. Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section. Nptel video courses pack pdf format nptel user pack.
Except the forging operation, all other metal forming process are used for producing uniform cross sectioned components only. Casting process exploit the fluidity of a metal in liquid state as it takes shape. Syllabus course contents materials and heat balance in metallurgical processes. Nocnon traditional abrasive machining processes ultrasonic, abrasive jet abrasive water jet machining. Machining is the process of removing the material in the form of chips by means of a wedge shaped tool. Manufacturing technology, me202e d24 notes unit v metal forming process mohammad amir, lecturer, department of mechanical engineering, bhcet, dhauj, faridabad121004 page 3 3. Manufacturing processes i mechanical engineering course from iit roorkee nptel lecture videos by dr. Press brake forming, explosive forming, hydro forming, electro hydraulic forming, and magnetic pulse forming. Manufacturing processes i nptel online videos, courses. The components with cross holes cannot be produced easily using metal forming process. The resin sets, binding the sand particles together and forming half of a strong mold. Americium is a synthetic radioactive chemical element with the symbol am and atomic number. Cutting and forming thin sheets of metal usually performed as cold working sheet metal 0. For the pass with the largest change of forming angle, the most significant fluctuation in rolling force is observed.
Me 206 manufacturing processes 1 department academic. Forming technology classification of metal working processes. Virtual engineering and planning process in sheet metal forming dr. Electroforming definition electroforming is a metal forming process that forms thin parts through the electroplating process. These videos are provided by nptel elearning initiative. This requirement can be acheived by manufacturing process such as forging, rolling,extrusion and drawing. Building materials and construction nptel online videos. Nov 10, 2017 in this video, i have discussed about the rolling process, definition of rolling process, types of rolling process.
Nptel syllabus manufacturing processes i video course metal forming elastic and plastic deformation. Using many of these pm processing techniques, as well as other processes such as spray forming, roll compaction, rapid solidification, and others, components are also produced today from particulate materials other than metal powders. Two halves and any desired cores are then assembled to form the mold, and this mold is backed up with moist sand for casting. Manufacturing processes i video lectures nptel videos.
Microfabrication processes, additive manufacturing. Metal casting process can be described as the process of making object by melting metal then poured into the desired mould. Shantanu bhattacharya nptel coordinating institute. Numerical simulation for the roll forming process of a. The course is meant as an introduction towards primary manufacturing processes such as casting, forming and welding. Mar 17, 2016 higher mount of force and energy is required for metal forming process compared to other manufacturing methods. Nptel video lectures, iit video lectures online, nptel youtube lectures. Plutonium is a radioactive chemical element with the symbol pu and atomic number 94. Processes likeabrasive jet machining water jet machininglaser beam machininghot machiningplasma arc machininghave also been included. They are mainly used to assemble many parts to make a system. Forging shop forging is a manufacturing process involving the shaping of metal using localized compressive forces. High energy rate forming processes lecture machining fundamentals lecture 14 machining.
Nptel provides elearning through online web and video courses various. Advantages can include a reduction in shrinkage and significantly reduced latent heat. Analysis and technology in metal forming 29 influence of strainrate i. Classification of engineering materials and processing techniques, structure and properties of nonmetals glass structure and properties, glass melting and forming, glass annealing classification of ceramics. In extrusion, for example, the flow stress considerably changes during the forming process as the material gets work hardened considerably.
Forging is often classified according to the temperature at which it is performed. Since the shear stress gets reduced at higher temperatures, the hot working requires much less force to achieve the necessary. Recent advances in metal forming processes authorstream presentation. The other forming processes or other manufacturing processes are like casting welding machining all that and there are other varieties. If coefficient of friction becomes very high it leads to a situation called sticking friction. Materials and energy balance in metallurgical processes. Lecture series on building materials and construction by dr. Chemistry cartridges feature test bank questions, lecture materials. Lecture 1 introduction to metal forming technology lecture 2 classification of metal working processes lecture 3 behavior of materials lecture 4. Design of machine elements nptel online videos, courses.
Bulk deformation forging processes extrusion processes wire and bar drawing rolling processes 2. In forming processes, such as forging, the instantaneous flow stress can be found from the flow curve, as the stress required to cause a given strain or deformation. Lecture series on manufacturing processes i by prof. Powder metallurgy pm is a metal working process for forming precision metal components from metal powders. Manufacturing process technology ii dvd media storage type. Advanced machining processes nptel online videos, courses iit video lectures. Nptel online videos, courses iit video lectures well organized. When atoms of nonmetal elements form ions, they generally gain enough electrons. The author has conducted research in metal forming and has taught the subjects of metal forming analysis and metal forming technology to the graduate and undergraduate students of iit bombay and iit delhi for a total period of more than 35 years, during which time, he also guided many ph. Little or no material is removed during the forming process. Metal forming is the main method of making metal products and semifinished products.
Numerical modeling of sheet metal forming processes. Aug 25, 2015 the numisheet conferences are established as a worldclass forum at which new ideas and technology in the area of sheet metal forming simulation are exchanged, making major contributions in the. Metal casting is a labour intensive process automation. Nptel, online courses and certification, learn for free. They produce permanent joint between the parts to be assembled. Apr 07, 20 nptel was the brainchild proposal which was put forward by the five main iits national program in technology enhanced learningnptel. For the aerospace industry in particular we can form both nearnetshapes out of thick plate and final product shapes out of sheet metal. Building materials and construction building materials and construction.
The course seeks to impart an understanding of those manufacturing methods traditionally not associated. A variant of sandcasting is the shellmolding process, in which a mixture of sand and a thermosetting resin binder is placed on a heated metal pattern. The advantages of metal forming processes include no wastage of the raw material, better mechanical properties of the product and faster production rate. The workpiece is completely or partially subjected to plastic deformation during the forming operation. Modern machining processes presents unconventional machining methods which are gradually commercial acceptance. Virtual engineering and planning process in sheet metal forming.
The term plastic deformation describes permanent shape change, in contrast to elastic deformation. They cannot be separated easily by application of forces. Metal forming and machining processes springerlink. The materails to be used in places where the component is subjected to very high impact load, shock load, intermittant load and in power transmission lines, need to be produced with dense grain structure. After this, i have discussed the types of rolling mils or rolling mill. Nptel syllabus advanced manufacturing processes video course course outline the course covers the details of the advanced machining theory and practices, advanced machining processes, advanced metal forming processes, advanced welding processes and advanced foundry processes. The pattern is made of wax or a plastic such as polystyrene. Chemistry, seventh edition westminster public schools. Our free textbooks go through a rigorous editorial publishing process. Beside the full 3d design process of parts and tools the simulation of sheet. The course contents and videos uploaded are free to download for all. Combining forging forming with alternative production technologies can enable next generation products opportunities exist to break the economic barrier of tooling and provide flexible and configurable methods it is and can be high value manufacturing really achieving advances in metal forming requires a total route to market.
Forming limit curves of advanced high strength steels supported by grants from the key laboratory of testing technology for manufacturing process southwest university of science and technology, ministry of education no. Design of machine elements nptel online videos, courses iit video lectures. Manufacturing process ii fundamentals of metal forming 1. Metal forming processes such as rolling, forging, extrusion etc. The rheo casting process involves using slurry in a semi solid state with the amount of benefits directly linked to the fraction solid at the time of casting. More than 90% of smelted metal is processed by different methods of metal forming. Hot and cold working processes rolling, forging, extrusion, swaging, wire and tube drawing. Find materials for this course in the pages linked along the left. Plastic properties of metals are used during the process of metal forming. Total 18 questions have been asked from load estimation for bulk forging, rolling, extrusion, drawing topic of casting, forming and joining processes subject in previous gate papers. Mod1 lec12 high energy rate forming processes youtube. Mechanical engineering manufacturing processes i nptel. It is really great that you are preparing using nptel. Learn for free, pay a small fee for exam and get a certificate.