Single-Course Engelsk 5 ECTS

Metal forming and joining technologies

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Overall Course Objectives

The overall objective of the course is to provide students with a physically based and engineering-oriented understanding of sheet metal forming and selected joining technologies, enabling them to analyze, design and integrate manufacturing process chains for industrial sheet metal components. Sheet metal forming includes the basics of metal plasticity and anisotropy to calculate stress and strain in processes, such as deep drawing and stretch forming. The joining processes include joining by plastic deformation (such as hemming and various types of riveting), resistance welding, and laser welding.

See course description in Danish

explain and compare the fundamentals of sheet metal forming and joining processes
apply simplified analytical models to estimate stresses, strains, forming limits and joining process windows
identify and explain critical process limitations in sheet metal forming, such as wrinkling, fracture, and excessive tool wear
identify and explain critical process limitations in joining processes, such as limited geometrical locking, splash/expulsion of molten metal, or porosity formation
design tools and plan process parameters for sheet metal forming and selected joining processes to stay within the respective process windows
plan and execute experimental work for studying manufacturing processes
apply commercial finite element software packages to simulate sheet metal forming and joining processes while evaluating and using results critically
evaluate process chains involving sheet metal forming and joining processes with respect to material combinations, process robustness, and final product properties
describe sustainability aspects in individual processes and at process chain level with focus on material use, energy use, and the consequences of the manufacturing stage on the environmental impact during the use phase of the product

Sheet metal forming involves analysis and design of processes such as deep drawing and stretch forming. Content and methods include basic metal plasticity, anisotropy, plastic instability and sheet formability, tribology (friction, lubrication and wear), tool design and introduction to the finite element method (FEM).
Joining technologies will be introduced in general and focus will be on those mostly combined with sheet formed parts, i.e., joining by plastic deformation (hemming, riveting, and clinching), resistance welding and laser welding. For the joining technologies, the focus will be on fundamental understanding, possible material combinations, geometrical constraints, process windows, and the relationship between process parameters and joint strength.
Combinations of processes will be analyzed as process chains, where one process will influence the next one. Sustainability aspects will be taught by published example calculations that will highlight important aspects to improve.
The course will be centered around project work, where the individual lectures, exercises, use of commercial software, and laboratory work all feed into the overall aim of the project.

41714/41787/41862/41502/41534

Lectures, problem solving, computer exercises and laboratory work.