Certification in Fundamentals of Metal Forming Processes

Forming Process also known as Metal Forming is a large set of manufacturing processes by which raw material is converted into a product. In this process, we apply stresses like tension, compression, shear, etc. to deformed the raw material. The example of forming processes are sheet metal manufacturing, forging, rolling, extrusion, wire drawing, and so onMetal forming processes are an essential part of our society, and without them, our society would come to a grinding halt. The products and components created by the different metal shaping techniques are used in creating everything from scaffolding and heavy machinery to designing and creating microprocessors and artificial intelligence. When it comes to metal forming, there are several processes to choose from, with each offering its own list of benefits and detriments, each suited to certain applications, and each suited for different types of metal.COURSE OUTLINEIntroduction to the Fundamentals of Metal Forming ProcessesFundamentals of metal formingTypes of deformation processes of metalBulk deformation (Rolling, Forging, Extrusion, Wire Drawing)Sheet metal workingStress-Strain CurveDerivation of the relation between stress and strainFlow stress and Average flow stressThe temperature in metal forming (Cold working and Hot-working)RecrystallizationIso thermal forming (recovery and Grain growth)Strain rate SensitivityRolling ProcessIntroduction of rollingShapes used for rollingTypes of rollingWorking on the rolling processAnalysis of the rollingRolling millsNo-Slip Point for rollingFlatness control and rolling defectNumerical Problems related to the rolling processForging ProcessIntroduction to forgingClassification of forgingTypes of forgingAnalysis of the forgingBarreling effect in forgingOpen Die forging and its practicesImpression Die forging and its practicesAdvantages and Limitations of Impression Die forgingFleshless forgingForging Press and Forging HammersNumerical Problems related to the forging processExtrusion ProcessIntroduction to the extrusion processClassification of extrusionDirect and Indirect extrusionHot and Cold extrusionDirect and Continuous extrusionAnalysis of the extrusion processEffect of friction on extrusionExtrusion Dies and OrificeExtrusion press and other extrusion processesNumerical Problems related to the extrusion processDrawing ProcessIntroduction to DrawingDifference between drawing and wire drawingBar DrawingWire DrawingFeatures of Draw DiePreparation of the workAnalysis of the drawing processSheet Metal Forming ProcessesSheet metal CuttingIntroduction to sheet metal cutting processCharacteristics of EdgesTypes of sheet metal cuttingShearingBlanking and PunchingClearance in Sheet metal cuttingAnalysis of sheet metal cutting processesNumerical Problems related to the sheet metal cutting processSheet Metal BendingIntroduction of sheet metal bending processTypes of sheet metal bendingAnalysis of the sheet metal bending processNumerical Problems related to the sheet metal bending processSpring BackSheet Metal DrawingIntroduction to the drawing processMechanics of drawingStages of deformationAnalysis of the drawing processTests of Drawing FeasibilityBlank force and blank size determinationNumerical Problems related to the drawing processRedrawing, Reverse Drawing and Drawing without Blank holderOther drawing processes (Redrawing, Reverse Drawing and Drawing without Blank holder)Defects in DrawingThe operation performed with metal toolingIroningCoining & EmbossingLancing & TwistingThe operation performed with flexible Rubber toolingGuerin and Hydroforming processNumerical Problems related to the other drawing processes