Metal Forming

This seminar covers metal forming and related manufacturing processes, emphasizing practical applications. From forged or P/M connecting rods to tailor-welded blank forming, metal parts are integral to the automotive industry. As a high value adding category of manufacturing, metal forming is increasingly important to the core competency of automobile manufacturers and suppliers. A thorough survey of metal forming processes and metal forming mechanics will be performed, including bulk deformation, sheet-metal, and powder metallurgy operations. Design considerations are fully integrated into the course and are presented with every process. A large number of real-world case studies are presented to the attendees to emphasize course content.

Attendees will receive a copy of the book "Manufacturing Engineering Technology," co-written by instructor Steven R. Schmid.

What Will You Learn

By attending this seminar, you will be able to:
  • Identify the unique characteristics of metals that lead to plastic deformation as a processing strategy
  • Explain the processes involved in metal forming mechanics, materials, and tribology
  • Analyze the interrelationships between various factors that influence the quality of manufactured products
  • Describe sheet metal characteristics and forming
  • Describe the wide variety of processes used to shape and deform metals, including forging, rolling and extrusion; sheet metal forming, shearing and stamping; powder metallurgy processes and assorted other processes

Is This Course For You

This course is designed for engineers who are involved in metal forming and other related manufacturing processes.

Materials Provided

This data is not available at this time

Course Requirements

This data is not available at this time

Topics

DAY ONE
  • Overview of Solid Mechanics and Materials Science Topics of Importance to Metal Forming
  • Tribology of Metal Forming: Friction, Lubrication and Wear
  • Bulk Deformation Processes
    • Forging: open die and closed-die (impression) forging; machinery description and capabilities; forging process layout and die design; heading, coining, piercing and upsetting operations; swaging
    • Rolling: flat rolling process, including Orowan model; control of product quality including surface finish and gage control; rolling equipment and capabilities; shape rolling; ring rolling
    • Extrusion and drawing: direct, indirect and hydrostatic extrusion; cold and hot extrusion; die design; defects in extrusion; drawing equipment and mechanics; limiting drawing ratio
DAY TWO
  • Sheet Metal Forming Processes
    • Sheet metal shearing: mechanics of shearing, burr formation, blanking operations, fine blanking
    • Sheet metal bending: types of bending operations and equipment; springback calculation and control; tube bending
    • Sheet forming operations: deep drawing and ironing; stretch forming; bulging, rubber forming and hydroforming; roll forming of sheet; spinning; incremental forming; explosive, peen and other specialty forming processes; stamping operations and die design
    • Sheet metal formability: limiting drawing ratio for deep drawing; sheet metal formability; forming-limit diagrams
  • Powder Metallurgy Processes
    • Compaction through pressing, cold and hot isostatic pressing and metal injection molding; sintering mechanics and processes; coining and finishing