Lovely Professional University, PunjabCourse Code Course Title Course Planner Lectures Tutorials Practicals CreditsMEC525 MECHANICS OF METAL FORMING 15854::Jasvinder Singh 2.0 0.0 0.0 2.0Course Category Courses with Numerical focus

TextBooks Sr No Title Author Edition Year Publisher NameT-1 MECHANICAL METALLURGY GEORGE E. DIETER 3rd 2013 M. G.HILLS

Reference BooksSr No Title Author Edition Year Publisher NameR-1 TECHNOLOGY OF METAL

FORMING PROCESSESSURENDER KUMAR 1st PHI (PRETICE HALL INDIA)

Relevant WebsitesSr No (Web address) (only if relevant to the course) Salient FeaturesRW-1 http://thelibraryofmanufacturing.com/forming_basics.html Information and description related to Forming

RW-2 http://www.efunda.com/formulae/solid_mechanics/mat_mechanics/calc_principal_stress.cfm

Stress calculator

RW-3 http://www.google.co.in/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&cad=rja&ved=0CDUQFjAB&url=http%3A%2F%2Facademic.uprm.edu%2Fpcaceres%2FCourses%2FMMII%2FIMoM-5A.pdf&ei=kWeEUsu1I4nGrAeRpIHoAw&usg=AFQjCNHo0WGreYWWXV-AGAgOx-PkhkQ4Yg&sig2=-2SOFiKHB7XaBE3R4hinjQ&bvm=bv.56343320,d.bmk

Principal stresses ans calculation

Week Number

Lecture Number

Broad Topic(Sub Topic) Chapters/Sections of Text/reference books

Other Readings,Relevant Websites, Audio Visual Aids, software and Virtual Labs

Lecture Description Learning Outcomes Pedagogical ToolDemonstration/ Case Study / Images / animation / ppt etc. Planned

Live Examples

Detailed Plan For Lectures

LTP week distribution: (LTP Weeks)Weeks before MTE 7

Weeks After MTE 7

Spill Over 2

Week 1 Lecture 1 Introduction and state of stresses(Cold,hot and warm forming and types of stresses)

R-1:1.2 and 1.3 Basic introductory partof the course and knowledge about forming process related with temperature

Basic understanding ofdifferent type ofForming processes

Figures of Forging processes

Making of rod and tubes

Introduction and state of stresses(Components and principle stresses)

R-1:2.2 Different components of stresses.

Basic understanding ofdifferent components of stresses.

Rectangular block representing stresses

stress produce during work

Lecture 2 Introduction and state of stresses(Experiments and bulk deformation processes)

T-1:18.1R-1:1.6 and 1.7

Different types of deformation processes like Extrusion, Drawing and rolling

Working of metal deforming processes.

Figures of different metal deformation processes

Introduction and state of stresses(Temperature and crack formation)

R-1:1.7 Relation between temperature and cracking in deformation processes.

Effect of temperature on cracking in deformation processes

Figures of different metal deformation processes

cracks of plastic when put in to sun light , braking of glass due to hot water

Week 2 Lecture 3 Stress and strain relationships and Elastic behaviours(Description of stress at a point)

T-1:2.2 Component of stresses Different type of stresses (normal and shear stresses)

Figure of stresses acting cube.

Stress and strain relationships and Elastic behaviours(state of stress in two and three dimensions)

T-1:2.3 and 2.5 Plane stresses in two and three dimensions

Calculation of stresses in two and three dimensions

Figure of stresses on oblique plane

Lecture 4 Stress and strain relationships and Elastic behaviours(state of stress in two and three dimensions)

T-1:2.3 and 2.5 Plane stresses in two and three dimensions

Calculation of stresses in two and three dimensions

Figure of stresses on oblique plane

Week 3 Lecture 5 Stress and strain relationships and Elastic behaviours(Mohr's circle of stress- two dimension and three dimension)

T-1:2.4 and 2.7R-1:2.7

Formation of mohr's circle

calculation of stresses with the help of mohr's circle

Figure of mohr's circle

Lecture 6 Stress and strain relationships and Elastic behaviours(Hydrostatics and Deviator components of stress)

T-1:2.10 Role of Hydrostatics and Deviator components of stress

Effect of stress components

figure of hydrostatic stresses

Stress and strain relationships and Elastic behaviours(Elastic stress strain relations)

T-1:2.11 Stress strain relation Knowledge about stress strain relationship

Hooke's law elastic and plastic body

Week 4 Lecture 7 Stress and strain relationships and Elastic behaviours(Calculations of stresses from elastic strains)

T-1:2.12 Stress strain relation Knowledge about stress strain relationship

Numerical relates to stress strain relation.

Lecture 8 Test1

Week 5 Lecture 10 Yield criteria and flow rules(Yield criteria of ductile metals)

T-1:3.4 Von Mises or Distortion-energy Criterion

Calculation of stresses for ductile materials

Equations of Von Mises

Lecture 9 Yield criteria and flow rules(Introduction)

T-1:3.1 Introduction about theory of plasticity

Knowledge about stress-strain curves

Figure of Stress-strain curves of different materials

Yield criteria and flow rules(The flow curve)

T-1:3.2 Description of flow curve

Knowledge about flow curve

Idealized flow curve

Yield criteria and flow rules(True stress and true strain)

T-1:3.3 Relation between true stress and true strain

Knowledge about stress-strain equations

Equations of stress-strain relation

deformation of object

Week 6 Lecture 11 Yield criteria and flow rules(Combined stress test)

Spill Over Spill Over Spill Over

Lecture 12 Yield criteria and flow rules(Yield locus)

T-1:3.5 and 3.6 Combined stress test and Yield locus

Calculations of stresses

Figure of Yield criteria for plane stresses

Yield criteria and flow rules(Anistropy in yielding)

T-1:3.7 Anistropy in yielding Calculations of stresses

Demonstration by Faculty

Yield criteria and flow rules(Yield surface and normality)

T-1:3.7 Yield surface and normality

Yield surface for Von Mises criterion

Figures of Yield Locus

Week 7 Lecture 13 Yield criteria and flow rules(Octahedral shear stress and shear strain)

T-1:3.9 shear stress and shear strain in Octahedral condition

Knowledge about the calculation of stress and strain

Demonstration by Faculty

Yield criteria and flow rules(Levy Mises equation)

T-1:3.11 Plastic stress-strain relation

Levy Mises equation Demonstration by Faculty

Yield criteria and flow rules(Prandtl Reuss equation)

T-1:3.11 Plastic stress-strain relation

Prandtl Reuss equation

Equations of Prandtl Reuss

Lecture 14 Yield criteria and flow rules(Slip line field theory)

T-1:3.12 Two - Dimensional plastic flow - Slip line field theory

Methods of developing plastic constraint

Figure of mohr's circle

MID-TERMWeek 8 Lecture 15 Forging and rolling of

metals(Classification of forging process)

T-1:16.1 Different types of forging processes

Uses of forging processes

Figure of different types of forging processes

Manufacturing of object by blacksmith

Forging and rolling of metals(Equipments)

T-1:16.2 Different types of forging equipments

Uses of forging equipments

Figure of different types of forging equipments

Forging and rolling of metals(Forging plain strain)

T-1:16.3 Calculation of forces in forging

Knowledge about different forces in forging

Figure of stress distribution

Lecture 16 Forging and rolling of metals(Open die and close die forging)

T-1:16.4 and 16.5 Description of open and closed die forging.

Knowledge about different types of forging dies

Figures of open and closed die forging.

Manufacturing of object by blacksmith

Forging and rolling of metals(Calculation of Forging)

T-1:16.6 Calculation of Forging loads in closed-die forging

Calculation of loads Figure of slab

Week 9 Lecture 17 Forging and rolling of metals(Hot rolling and cold rolling)

T-1:17.3 and 17.4 Hot and cold rolling Different types of rolling

Figures of Rolling mill

Manufacturing of object by blacksmith

Forging and rolling of metals(Rolling of bar and shapes)

T-1:17.5 Methods of rolling Different types of rolling

Figures of Rolling mill

similar process as sugar cane

Forging and rolling of metals(Forces and geometrical relationship in rolling)

T-1:17.3 and 17.4 Geometric relationship in rolling

Calculations related to rolling

Figures of forces acting during rolling

Lecture 18 Forging and rolling of metals(Analysis of rolling load)

T-1:17.7 Analysis of rolling loads Knowledge about the calculation of rolling lodes

Figures used to define the rolling loads

Week 10 Lecture 19 Test2

Lecture 20 Extrusion and Drawing(Classification o f Extrusion process)

T-1:18.1 Different types of extrusion processes

Knowledge about extrusion processes

Figure of extrusion processes

making of sheets at jindal aluminum factory

Extrusion and Drawing(Deformation lubrication and Defects in extrusion)

T-1:18.4 Different types of lubrication and defects in extrusion processes

Knowledge about lubrication and defects in extrusion processes

Figure of extrusion processes

Extrusion and Drawing(Analysis of extrusion process)

T-1:18.5 Analysis of extrusion process

Knowledge about different forces in extrusion

Figure of stress-strain distribution in partial tube

Week 11 Lecture 21 Extrusion and Drawing(Hydrostatic extrusion)

T-1:18.7 Use of hydro pressure in extrusion

Role of hydrostatic pressure in extrusion

Figures of extrusion processes

Extrusion and Drawing(Rod and wire drawing)

T-1:19.2 Different types of drawing processes

Use and working of drawing process equipments

Figures of different drawing processes

Extrusion and Drawing(Analysis of wire drawing)

T-1:19.3 Analysis of forces acting during process

Knowledge related forces in wire drawing

Figures of wire drawing processes

Lecture 22 Extrusion and Drawing(Tube drawing process)

T-1:19.4 Types of tube drawing processes

Knowledge about tube drawing

Figure of tube drawing processes

Extrusion and Drawing(Analysis of tube drawing)

T-1:19.5 Analysis of forces acting during process

Knowledge related forces in tube drawing

Figure of tube drawing processes

Week 12 Lecture 23 Test3

Lecture 24 Sheet metal Forming and Lubrication mechanisms(Forming methods)

T-1:20.1 and 20.2 Introduction and methods of forming processes

Different types of forming processes

Figures of different forming processes

Sheet metal Forming and Lubrication mechanisms(Shearing and Blanking)

T-1:20.3 Introduction and methods of shearing and blanking processes

Different types of shearing and blanking processes

Figures of different shearing and blanking processes

Manufacturing of object by blacksmith

Week 13 Lecture 25 Sheet metal Forming and Lubrication mechanisms(Bending)

T-1:20.4 Definition of terms used in bending

Springback in bending

Different types of bending processes

Manufacturing of object by blacksmith

Sheet metal Forming and Lubrication mechanisms(Stretch forming)

T-1:20.5 Stretch forming operation

Variation of necking Figures of stretching processes

Lecture 26 Sheet metal Forming and Lubrication mechanisms(Deep drawing)

T-1:20.6 Description of Deep drawing

Analysis of deep drawing process

figures of different drawing processes

making of tube

Sheet metal Forming and Lubrication mechanisms(Forming limit criteria)

T-1:20.7 Description forming limit

Analysis of forming limit

Forming limit diagram

Week 14 Lecture 27 Sheet metal Forming and Lubrication mechanisms(Lubrication principle and mechanism)

R-1:7.2 and 7.3 Lubrication principals and mechanism

Knowledge about lubrication mechanism

Figure of three regimes of lubrication

Sheet metal Forming and Lubrication mechanisms(Lubrication need and their components and cost selection)

R-1:7.4 and 7.5 Need of lubrication in industries

Knowledge about costs of lubrication

Different components of costs in lubrication

Lecture 28 Sheet metal Forming and Lubrication mechanisms(Chemical characteristics and solid lubrication)

R-1:7.10 and 7.11 Chemical characteristics values and categories of solid lubrication

Types of solid lubrication

Demonstration by Faculty

Sheet metal Forming and Lubrication mechanisms(classification of lubricants and use in forming process)

R-1:7.7 and 7.8 classification of lubricants

Use of lubrication in forming process

Demonstration by Faculty

SPILL OVERWeek 15 Lecture 29 Spill Over

Lecture 30 Spill Over

Scheme for CA:Component Frequency Out Of Each Marks Total Marks

Test 2 3 10 20

Total :- 10 20

Details of Academic Task(s)

AT No. Objective Topic of the Academic Task Nature of Academic Task(group/individuals/field

work

Evaluation Mode Allottment / submission Week

Test1 To check student's ability to understand subject matter through written test

Unit 1 and Unit 2 Individual Answers should be to the point and problems should be solved step wise.

3 / 4

Test2 To check the understanding of students about the topics done in class

Unit : 4 Individual Answers should be to the point and problems should be solved step wise.

9 / 10

Test3 To test the knowledge of the student

Unit : 5 Individual Answers should be to the point and problems should be solved step wise.

11 / 12