Lovely Professional University, Punjab

Course Code

Course Title

Course Planner

Lectures

Tutorials Practicals Credits

MEC525

MECHANICS OF METAL FORMING

16845::Pankaj Kumar

Course Orientation

1 :DISCIPLINE KNOWLEDGE, 5 :PLACEMENT EXAMINATION, 7 :COMPETITIVE EXAMINATION(Higer Education), 8

:COMPETITIVE EXAMINATION(Civil Services)

3.0

TextBooks
Sr No

Title

Author

Edition

Year

Publisher Name

T-1

MECHANICAL METALLURGY

GEORGE E. DIETER

3rd

2013

MCGRAW HILL EDUCATION

Year

Publisher Name

Reference Books
Sr No

Title

Author

Edition

R-1

TECHNOLOGY OF METAL
FORMING PROCESSES

SURENDER KUMAR

1st

R-2

A textbook of Production Engineering P.C. Sharma

11th

PRENTICE HALL
1982

S. CHAND & COMPANY

Relevant Websites
Sr No

Web address (only if relevant to the course)

Salient Features

RW-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_stres Stress calculator

s.cfm

RW-3

http://www.google.co.in/url?
Principal stresses and calculation
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%2FIMoM5A.pdf&ei=kWeEUsu1I4nGrAeRpIHoAw&usg=AFQjCNHo0WGreYWWXVAGAgO
x- PkhkQ4Yg&sig2=-2SOFiKHB7XaBE3R4hinjQ&bvm=bv.56343320,d.bmk

LTP week distribution: (LTP Weeks)

Detailed Plan For Lectures

Weeks before MTE

Weeks After MTE

Spill Over

0.0

0.0

3.0

Week
Lecture
Number Number

Broad Topic(Sub Topic)

Week 1

Lecture 1

Introduction and state of

stresses(Strength of
material-basic assumptions)

Lecture 2

Introduction and state of

stresses(Elastic and plastic
behavior of metals)

T-1:1

Behavior of materials in Learning of material PPT and

elastic and plastic region characteristics
Discussion

Introduction and state of

stresses(Average stress and
strain)

T-1:1

Average stress and

strain

Learning of stress
and strain concepts

Introduction and state of

stresses(Tensile deformation
of ductile metals)

T-1:1

Tensile deformation of
metals

Stress strain diagram PPT

Tensile test
UTM

Introduction and state of

stresses(Ductile vs Brittle
behavior)

T-1:1

RW-1

Ductile vs Brittle
behavior

Behavior of metals in PPT

ductile and brittle
region

Tensile test
UTM

Lecture 4

Introduction and state of

stresses(Cold,hot and warm
forming and types of
stresses)

R-1:1

RW-1

Cold working and Hot

working

Learning of
PPT and
recrystallisation
Discussion
temperature. Change
in grain structure
with temperature

Martensite in
TTT diagram

Lecture 5

Introduction and state of

stresses(Experiments and
bulk deformation processes)

T-1:18
R-1:1

RW-1

Different types of
Working of metal
Figures of different Extruded
deformation processes deforming processes. metal deformation products like
like Extrusion, Drawing
processes
hollow pipes
and rolling

Introduction and state of

stresses(Temperature and
crack formation)

R-1:1

RW-1

Relation between
temperature and
cracking in deformation
processes.

Lecture 6

Introduction and state of

stresses(Components and
principle stresses)

R-1:2

RW-1

Different components of Basic understanding Rectangular block

stresses.
of
representing
different components stresses
of
stresses.

Lecture 7

Stress and strain

relationships and Elastic
behaviours(Description of
stress at a point)

T-1:2

Lecture 3

Week 2

Week 3

Chapters/Sections of Other Readings,

Text/reference
Relevant Websites,
books
Audio Visual Aids,
software and Virtual
Labs

Lecture Description

Learning Outcomes Pedagogical Tool Live Examples

Demonstration/
Case Study /
Images /
animation / ppt
etc. Planned

Lecture Zero

Knowledge of basics PPT and

of metal forming
Animations
techniques and basic
overview of course

Component of stresses

Stress-Strain
diagram for
ductile material

Discussion

Effect of temperature Figures of different

on cracking in
metal deformation
deformation
processes
processes

Different type of
stresses (normal and
shear stresses)

auto mobile
components
made from
metal forming
processes like
crankshaft,
piston

Figure of stresses
acting cube.

Week 3

Week 4

Lecture 8

Stress and strain

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

T-1:2

Plane stresses in two

and three dimensions

Calculation of
stresses in two and
three
dimensions

Lecture 9

Stress and strain

relationships and Elastic
behaviours(Mohr's circle of
stress in two dimension)

T-1:2
R-1:2

Formation of mohr's
circle with numericals

Calculation of
Figure and
stresses with the help Discussion
of mohr's circle.
Numerical problems

Lecture 10 Stress and strain

relationships and Elastic
behaviours(Hydrostatics and
Deviator components of
stress)
Stress and strain
relationships and Elastic
behaviours(Elastic stress
strain relations)
Lecture 11 Stress and strain
relationships and Elastic
behaviours(Calculations of
stresses from elastic strains)

T-1:2

RW-3

Role of Hydrostatics and Effect of stress

Deviator components of components
stress

Sketches and
Discussion

T-1:2

RW-1

Stress strain relation

Hooke's law

T-1:2

RW-2

Numerical problems on Knowledge about

Stress strain relation
stress strain
relationship

Lecture 12
Week 5

Week 6

Figure of stresses
on oblique plane

Knowledge about
stress strain
relationship

Digram between
stress strain

Numerical

Test1

Lecture 13 Yield criteria and flow rules

(Introduction)

T-1:3

Yield criteria and flow rules

(The flow curve)

RW-1

Introduction about
theory of plasticity

Introduction about
theory of plasticity

Figure of Stress
Tensile test on
strain
UTM
curves of different
materials

T-1:3

Description of flow
curve

Knowledge about
flow curve

Idealized flow
curve

Tensile test on
UTM

Lecture 14 Yield criteria and flow rules

(True stress and true strain)

T-1:3

Relation between true

stress and true strain

Knowledge about
stress-strain
equations

Discussion

Equations of
stress strain
relation

Lecture 15 Yield criteria and flow rules

(Yield criteria of ductile
metals)

T-1:3

Von Mises or
Distortion energy
Criterion. Tresca Yield
criteria

Calculation of
stresses for ductile
materials

Discussion
Equations of Von
Mises and tresca

Lecture 16 Yield criteria and flow rules

(Combined stress test)

T-1:3

Combined stress test

Combination of
Discussion
different stresses and
yield criteria

Yield criteria and flow rules

(Octahedral shear stress and
shear strain)

T-1:3

Shear stress and shear

strain in Octahedral
condition

Knowledge about the Demonstration by

calculation of stress Faculty
and
strain

Lecture 17 Yield criteria and flow rules

(Invariants of stress and
strain)

T-1:3

Invariants of stress and

strain

Invariants of stress
and strain

Yield criteria and flow rules

(Levy Mises equation)

T-1:3

Plastic stress-strain
relation

Levy Mises equation Discussion and

demonstration by
faculty

Discussion

Torsion test

Week 6

Lecture 18 Yield criteria and flow rules

(Prandtl Reuss equation)

T-1:3

Plastic stress-strain
relation

Prandtl Reuss
equation

Discussion and
demonstration by
faculty

Week 7

Lecture 19 Yield criteria and flow rules

(Slip line field theory)

T-1:3

Two Dimensional
plastic flow Slip line
field theory

Methods of
developing
plastic constraint

Sketches and
Discussion

SPILL OVER
Week 7

Lecture 20

Spill Over

Lecture 21

Spill Over

MID-TERM
Week 8

Lecture 22 Forging and rolling of

metals(Classification of
forging process)

T-1:16

Different types of
forging processes

Uses of forging
processes

Figure of different Crankshafts

types of forging
processes

T-1:16

Different types of
forging equipments

Uses of forging
equipments

Figure of different Hydraulic and

types of forging
mechanical
equipments
forging press

T-1:16

Forging plain strain

Calculation of forces Demonstration by

in forging
faculty

T-1:16

Description of open and Knowledge about

closed die forging.
different types of
forging dies

Figures of open
and closed die
forging.

Lecture 24 Forging and rolling of

metals(Analysis of Closed
die forging by slab method)

R-2:13

Analysis of open die

forging with sticking
friction

Numerical problem
for solving pressure
distribution that is
friction hill

Demonstration by
faculty

Lecture 25 Forging and rolling of

metals(Calculation of
Forging loads in closed die
forging)

T-1:16

Calculation of Forging
loads in closed-die
forging

Numerical
Calculation of loads

Numerical

Lecture 26 Forging and rolling of

metals(Hot rolling and cold
rolling)

T-1:17

RW-1

Hot and cold rolling

Different types of
rolling

Figures of Rolling Thin sheets

mill

T-1:17

RW-1

Methods of rolling

Different types of
rolling

Figures of Rolling
mill

R-2:13

Analysis of Rolling

Derivation of rolling Demonstration by

load with concepts of faculty
neutral point

Week 10 Lecture 28 Forging and rolling of

metals(Calculation of rolling
load)

T-1:17

Calculation of forging
load

Derivation

Demonstration by
faculty

Forging and rolling of

metals(Numerical Problems)

T-1:17

Numerical problem on
rolling

Numerical problem

Demonstration by
faculty

Forging and rolling of

metals(Equipments)
Lecture 23 Forging and rolling of
metals(Forging plain strain)
Forging and rolling of
metals(Open die and close
die forging)

Week 9

Forging and rolling of

metals(Rolling of bar and
shapes)
Lecture 27 Forging and rolling of
metals(Forces and
geometrical relationship in
rolling)

Lecture 29

Test2

Engine blocks

Week 10 Lecture 30 Extrusion and Drawing

(Classification of Extrusion
process)

T-1:18

Week 11 Lecture 31 Extrusion and Drawing

(Analysis of extrusion
process)

Different types of
extrusion and drawing
processes

Uses of extrusion
processes

Figure of different Tooth-paste

types of forging
processes

T-1:18

Analysis of extrusion
process

Knowledge about
different forces in
extrusion

Figure of stress
strain distribution
in partial tube

Lecture 32 Extrusion and Drawing

(Defects in extrusion)

T-1:18

Different types of
lubrication and defects
in
extrusion processes

Knowledge about
lubrication and
defects in extrusion
processes

PPT

Extrusion and Drawing

(Hydrostatic extrusion)

T-1:18

Use of hydro pressure in Role of hydrostatic

PPT
extrusion processes
pressure in extrusion

T-1:19

Different types of
drawing processes

T-1:19

Analysis of forces acting Knowledge related

process
forces in wire
drawing

Faculty
demonstration by
faculty

T-1:19

Types of tube drawing

processes

PPT

T-1:19

Analysis of forces acting Knowledge related

during process
forces in tube
drawing

Faculty
demonstration

Numerical problem on
extrusion and drawing

Problem solution

Numerical

Different types of
sheet forming
processes

Figures of different Perforation

sheet forming
processes

Lecture 33 Extrusion and Drawing(Rod

and wire drawing)
Extrusion and Drawing
(Analysis of wire drawing)
Week 12 Lecture 34 Extrusion and Drawing
(Tube drawing process)
Extrusion and Drawing
(Analysis of tube drawing)
Lecture 35 Extrusion and Drawing
(Numerical problems)

T-1:19

RW-1

RW-1

Lecture 36

Use and working of

drawing process
equipments

Knowledge about
tube drawing

Wrinkles and
distortion defect

Figures of different
drawing processes
and PPT

Wires

Test3

Week 13 Lecture 37 Sheet metal Forming and

Lubrication mechanisms
(Forming methods)

T-1:20

RW-1

Introduction and
methods of sheet
forming processes

Sheet metal Forming and

Lubrication mechanisms
(Shearing and Blanking)

T-1:20

RW-1

Introduction and
Different types of
methods of shearing and shearing and blanking
blanking processes
processes

Figures of different Washers

shearing and
blanking
processes

Sheet metal Forming and

Lubrication mechanisms
(Bending)

T-1:20

RW-1

Definition of terms used Springback in

in bending
bending

Different types of
bending processes

Lecture 38 Sheet metal Forming and

Lubrication mechanisms
(Stretch forming)

T-1:20

RW-1

Stretch forming
operation

Variation of necking Figures of

stretching
processes

Sheet metal Forming and

Lubrication mechanisms
(Deep drawing)

T-1:20

RW-1

Description of Deep
drawing

Analysis of deep
drawing

Figures of different Bottles and deep

drawing processes cup

Sheet metal Forming and

Lubrication mechanisms
(Forming limit criteria)

T-1:20

RW-1

Description forming
limit

Analysis of forming
limit

Forming limit
diagram

Week 13 Lecture 39 Sheet metal Forming and

Lubrication mechanisms
(Lubrication principle and
mechanism)
Sheet metal Forming and
Lubrication mechanisms
(Lubrication need and their
components and cost
selection)
Week 14 Lecture 40 Sheet metal Forming and
Lubrication mechanisms
(Chemical characteristics
and solid lubrication)
Sheet metal Forming and
Lubrication mechanisms
(classification of lubricants
and use in forming process)

R-1:7

Lubrication principle
and mechanism

Knowledge about
lubrication
mechanism

Figure of three
regimes of
lubrication

R-1:7

Need of lubrication in
industries

Knowledge about
costs of lubrication

Different
components of
costs in lubrication

R-1:7

Chemical characteristics Types of solid

values and categories of lubrication
solid lubrication

R-1:7

classification of
lubricants

SPILL OVER
Week 14 Lecture 41

Spill Over

Lecture 42

Spill Over

Week 15 Lecture 43

Spill Over

Lecture 44

Spill Over

Lecture 45

Spill Over

Scheme for CA:

Component
Test

Frequency

Out Of
2

3
Total :-

Details of Academic Task(s)

Each Marks Total Marks

10

20

10

20

Demonstration by
Faculty

Use of lubrication in Demonstration by

forming process
Faculty

Grease

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

Strength of material-basic assumptions, Elastic and plastic

Individual
behavior of metals, Average stress and strain, Tensile deformation
of ductile metals, Ductile vs Brittle behavior, Cold,hot and warm
forming and types of stresses, Components and principle stresses,
Experiments and bulk deformation processes, Temperature and
crack formation. Description of stress at a point, state of stress in
two and three dimensions, Stress tensor, Mohr's circle of stresstwo dimension, Hydrostatics and Deviator components of stress,
Elastic stress
strain relations, Calculations of stresses from elastic strains,
Strain energy

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

Introduction, The flow curve, True stress and true strain, Yield
Individual
criteria of ductile metals, Combined stress test, Yield locus,
Anistropy in yielding, Yield surface and normality, Octahedral
shear stress and shear strain, Invariants of stress and strain, Levy
Mises equation, Prandtl Reuss equation, Slip line field theory.
Classification of forging process, Equipments, Forging plain
strain, Open die and close die forging, Analysis of Closed die
forging by slab method, Calculation of Forging loads in closed die
forging, Hot rolling and cold rolling, Rolling of bar and shapes,
Forces and geometrical relationship in rolling, Calculation of
rolling load, Numerical Problems

Answers should be
to the point and
problems should be
solved step wise.

9 / 10

Test3

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

Classification of Extrusion process, Deformation lubrication and Individual

Defects in extrusion, Analysis of extrusion process, Hydrostatic
extrusion, Rod and wire drawing, Analysis of wire drawing, Tube
drawing process, Analysis of tube drawing

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

11 / 12