ABOUT THE COURSE:Sheet metal forming processes are useful in manufacturing components in automotive, aerospace, defense and stamping industries. The components are used in automobiles, household items, space equipment, defense equipment, and several others. There is a need to understand the mechanics part of the sheet forming processes such as deep drawing, stretch forming, bending, hydroforming, along with basic plasticity. This course will provide such details through theoretical analyses and numerical problems, along with basic concepts in metal forming. The first part of the course deals with several concepts in metal forming and plasticity, and the second part includes theoretical analyses of few sheet forming and tube forming operations. The course will be useful to design engineers, stamping engineers, manufacturing students and scholars, and academia. Through this course, participants will be able to apply basic concepts for modeling any manufacturing processes involving plastic deformation.INTENDED AUDIENCE: Students (UG, PG), Researchers, Industry expertsPREREQUISITES: UG courses on Solid MechanicsINDUSTRY SUPPORT:Several industries such as Tata Motors, Tata Steel, Mahindra, Ashok Leyland, SAIL, BHEL, DRDO, IGCAR, BARC will recognize/value the online course.Several stamping/sheet forming industries and their engineers will find the course useful.
Overview
Syllabus
Week 1: Description of Material propertiesLecture 1 : Introduction, Tensile testLecture 2:Effect of properties on forming and formability
Week 2: Sheet deformation processesLecture 3 : Uni-axial tension, general sheet forming processes, yieldingLecture 4 : flow rule, work hardening hypothesis, work of plastic deformation, isotropic yield functionsLecture 5 : isotropic yield functions, effective stress and strain
Week 3: Sheet deformation in plane stressLecture 6 : strain distributions, strain diagram, deformation modesLecture 7 : effective stress-strain laws, principal tensions
Week 4: Stamping analysisLecture 8 : 2-D modeling of stamping, stretch and draw ratios in stamping.
Week 5: Load instability and tearingLecture 9 : uniaxial tension of perfect strip and imperfect stripLecture 10 : tensile instability in stretching continuous sheetLecture 11 : tensile instability in stretching continuous sheet
Week 6: Sheet formabilityLecture 12 : Forming limit curve – concept and evaluationLecture 13 : FLC, formability tests, theoretical prediction, factors affecting FLC
Week 7: Sheet bendingLecture 14 : Variables in bending a continuous sheet, equilibrium conditionsLecture 15 : material models, bending without tension, springback prediction
Week 8: Cylindrical deep drawing & Stretching circular shellsLecture 16 : Drawing the flange, cup heightLecture 17 : redrawing cylindrical cups, wall ironing of deep drawn cupsLecture 18 : Analysis of bulging with fluid pressure, stretching over punchLecture 19 : HydroformingLecture 20 : Demonstration on sheet forming operations -stretching, bending, deep drawing.
Week 2: Sheet deformation processesLecture 3 : Uni-axial tension, general sheet forming processes, yieldingLecture 4 : flow rule, work hardening hypothesis, work of plastic deformation, isotropic yield functionsLecture 5 : isotropic yield functions, effective stress and strain
Week 3: Sheet deformation in plane stressLecture 6 : strain distributions, strain diagram, deformation modesLecture 7 : effective stress-strain laws, principal tensions
Week 4: Stamping analysisLecture 8 : 2-D modeling of stamping, stretch and draw ratios in stamping.
Week 5: Load instability and tearingLecture 9 : uniaxial tension of perfect strip and imperfect stripLecture 10 : tensile instability in stretching continuous sheetLecture 11 : tensile instability in stretching continuous sheet
Week 6: Sheet formabilityLecture 12 : Forming limit curve – concept and evaluationLecture 13 : FLC, formability tests, theoretical prediction, factors affecting FLC
Week 7: Sheet bendingLecture 14 : Variables in bending a continuous sheet, equilibrium conditionsLecture 15 : material models, bending without tension, springback prediction
Week 8: Cylindrical deep drawing & Stretching circular shellsLecture 16 : Drawing the flange, cup heightLecture 17 : redrawing cylindrical cups, wall ironing of deep drawn cupsLecture 18 : Analysis of bulging with fluid pressure, stretching over punchLecture 19 : HydroformingLecture 20 : Demonstration on sheet forming operations -stretching, bending, deep drawing.
Taught by
Prof. R Ganesh Narayanan
