Single-Course English 5 ECTS

Industrial forming of metals

Overall Course Objectives

To enable the students to analyse complex bulk and sheet metal forming processes by theoretical/numerical methods.
To apply these analyses in: 1) determining the conditions in the interior of the material during as well as after processing, 2) determining favorable process and tool parameters and materials and 3) designing and dimension metal forming tools.

analytically describe isotropic and anisotropic materials characteristics
apply the slab method and upper bound method to plane and rotational symmetric forming operations
select appropriate tool materials for metal forming
calculate strains, strain rates and stresses during deformation
calculate resulting properties such as flow stress and hardness distribution of metal formed components
calculate limits of formability as function of material and process parameters
design and dimension tools for metal forming
suggest appropriate forming processes for specific components
optimize forming processes including multistep operations

1) Bulk metal forming: theoretical/numerical methods of analysis, drawing of rod and wire (process planning and optimization), cold, warm and hot extrusion and closed die forging (workpiece and tool materials and coatings, process analysis, tool design and dimensioning). 2) Sheet metal forming: modelling and testing of anisotropy, theoretical instability, testing of formability, process analysis of deep drawing and stretch forming. 3) Types of presses and selection of presses for different forming operations.

41704/41784/41713/41714/41781/41787/41788/41502/41534

Lectures, problem solving, laboratory demonstrations and exercises.