Unit 1
Fundamentals of Metal Forming: Theory of Plasticity – stress tensor – Invariants of stress strain – hydrostatic & deviator components of stress – flow curve – true stress and true strain. Yielding criteria – yield locus – octahedral shear stress and shear strains. Plastic deformations of crystals – critical resolved shear stress. Metal working: mechanics of metal working – working temperature – strain rate effects – friction and lubrication – deformation zone geometry.
Unit 2
Forging and Rolling Processes: Forging process – classification – equipment – calculation of forging loads – forging defects – residual stresses. Rolling: classification – rolling mills – rolling of bars & shapes – rolling forces – analysis of rolling – defects in rolling – theories of hot & cold rolling – torque power estimation.
Extrusion and Drawing Processes: Extrusion: classification – equipment – Analysis of extrusion process – extrusion defects – hydrostatic extrusion – tube extrusion. Drawing: Classification – rod & wire drawing equipment – analysis. Deep drawing – tube drawing – analysis, residual stresses.