Under the action of such forces, the shape and size of metal piece undergo a change. Bulge forming of tubes bft liquid bulge forming lbf hydraulic pressure forming hpf internal high pressure forming ihpf. Eme012pur40911re 1 turn over following paper id and roll no. The temperature of work is increases due to adiabatic heating. High energy rate forming herf processes introduction. For most metalforming processes, when the total strain is plotted against the homogeneous deformation, the former increases at a higher rate than would be expected for an efficient forming process. Sep 29, 2015 comparison of metal forming processescomparison of metal forming processes 34. Classification of unconventional machining processes was mainly on the basis of the nature of energy employed in machining process. Classification of unconventional machining processes.
Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. Cutting off, blanking, punching and piercing process 2. Sheet metal operations other sheet metal forming processes. The relationship is practically linear, but the ratio of the two quantities, for any given value of the homogeneous deformation, can be high.
Ultrasonic metal forming is the application of ultrasonic vibrations to these processes to enhance performance through increased production speeds, less tool wear, reduced forming forces, and better surface finish. Dec 31, 2016 unconventional metal forming processes 12312016 jit 1 unit v by. Jain department of mechanical engineering, indian institute of technology kanpur, kanpur208016, india. Electro chemical machining ecm, micro electrochemical machining, electroforming the journals and reports also cover the hybrid approach being taking place by combining different actions to make use of the combined advantages and to avoid or reduce some adverse effects the. In this process the high energy released due to explosion of an explosive is. Sheet metal forming processes have been classified into conventional and unconventional forming processes. It is a process of changing the shape and size of the material under the influence of external force or stress. In the manufacturing processes described thus far, the raw materials used have been metals and alloys either in a molten state casting or in solid form metalworking. In these processes, unconventional sources of energy such as explosive forming, electrohydraulic forming, magnetic pulse forming, petroforge and drop hammer and dynapak etc. Manufacturing process ii fundamentals of metal forming 1 introduction metal forming includes a large group of manufacturing processes in which plastic deformation is used to change the shape of metal workpieces. On this channel you can get education and knowledge for general issues and topics. Chemical methods of unconventional manufacturing processes are.
The release of energy is at extremely high rate and hence the name high energy rate forming. Tube hydroforming is one of the most popular unconventional metal forming processes which is widely used to form various tubular components. Other unconventional manufacturing processestechniques 1 4. Sheet metal forming processes almustansiriya university. Unconventional sheet metal forming processes are more and more employed in the automotive and aircraft industries in order to prod uce large body panels. Download free sample and get upto 37% off on mrprental. While making a part from raw material, one may require bulk removal of material, forming cavitiesholes and finally finishing as per the parts requirements.
Recent developments in metal forming technology lead to the development of a new group of metal forming processes entitled sheetbulk metal forming. Material removal processes once again can be divided into two groups 1. Thus we have both hot and cold metal forming operations. They include a very wide range of consumer and industrial products, such as beverage cans, cookware, file cabinets, metal desks, appliances, car bodies figure 9. Metal forming processes indian institute of technology. Pdf major, recent developmental trends in the field of metal forming are presented in the paper both. Unconventional forming free download as powerpoint presentation. Manufacturing process ii fundamentals of metal forming 1. Tube hydroforming thf has been called by many other names such as.
First, progress made in metal forming processes such as. We also use unconventional machining processes to machine soft materials, in order to get better dimensional accuracy. Where possible, the limits governing each process are identi. Electromagnetic forming em forming or magneforming is a type of high velocity, cold forming process for electrically conductive metals, most commonly copper and aluminium.
Advances in sheet metal forming technologies 63 fig. Unconventional forming explosive material inductor free. Stresses beyond yield strength of the workpiece material is required. Unconventional metal forming process linkedin slideshare. Tube spinning is used in forming of rocket parts, automotive components etc. Forming, metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation. The main reasons for choosing nontraditional machining processes are.
Unconventional metal forming or high energy rate forming herf processes such as explosive forming, electromagnetic, electrohydraulic forming. Metal forming process an overview sciencedirect topics. Metal forming processes full notes ebook free download pdf. In these cases, forming in higher temperatures 79, superplastic forming spf 10 11, high.
Highquality joints can be formed, either by electromagnetic pulse crimping with a mechanical interlock or by electromagnetic pulse welding with a true metallurgical weld. Sheetmetal forming includes cutting and forming operations performed on relatively thin sheet of metal typical sheet metal thicknesses. Self reading for your interestself reading for your interest defects in metal forming processesdefects in metal forming processes and their remedies. In this sense, they are no more unconventional or nontraditional. In these processes, unconventional sources of energy such as explosive forming, electrohydraulic forming, magnetic pulse forming, petroforge and drop. Pdf recent development trends in metal forming researchgate. Unconventional machining processes can be broadly classified into several types based on four main criteria. By this process, tubes are formed into different shapes. The availability of a wide range of metalpowder compositions, the ability to produce parts to net dimensions netshape forming.
Bending, stretching and drawing of simple shapes are analysed, as are certain processes for forming thinwalled tubing. Forming process requires stress above flow stress of the material being deformed. This process first was used by the egyptians in about 3000 b. The fundamental of metal forming theory, the theories of processes of rolling, forging and stamping as well as drawing and pressing extrusion have been given. Forming operates on the materials science principle of plastic deformation, where the physical shape of a material is permanently deformed. The forming processes are affected by the rates of strain used.
Improved lubrication if lubricating film is maintained. The effect of external work done on work piece during forming is converted into heat. Feb 27, 2017 on this channel you can get education and knowledge for general issues and topics. The following processes arc prominent in herf or unconventional forming processes. Pdf mechatronic contouring system for unconventional sheet. Development of unconventional forming methods journal of. Unconventional machining processes introduction and. Numerous technological forming processes achieve deform ations, which are. Nontraditional manufacturing processes or unconventional machining processes conventional machining processes mostly remove material in the form of chips by applying forces on the work material with a wedge shaped cutting tool that is harder. Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section.
Introduction to powder metallurgy manufacturing process. The term pressworking or press forming is used commonly in industry to describe general sheetforming operations. Unconventional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be used for. Unconventional forming explosive material inductor. Metal forming, press working and micro finishing processes. Draw beads a schematic illustration of a draw bead. Metals are generally deformed at specific temperature and strain rate so that recovery takes place simultaneously with the deformation. Mechanics of sheet metal forming college of engineering. Jan 20, 2018 unconventional metal forming processes. Body language how to read others thoughts by their gestures, allan pease, jacqueline kent. The unconventional manufacturing processes can be classified according to the source of energy used to generate machining action to following groups.
Download theory of plasticity and metal forming processes. The main difference between conventional and unconventional forming is the type of tools used in the process. The term pressworking or press forming is used commonly. The characteristics of the shop equipment for metal forming and technology of the main metal forming methods have been given in separate sections. Unit5 unconventional manufacturing processes capacitor. For a given metal or alloy, the low forming temperature limit depends also on. This book addresses issues essential to unconventional machining processes, covering all modern machining processes such as mechanical processes, electrochemical and chemical metal removal processes, and thermal metal removal processes. By this process, tubes are formed into different shapes using internal pressure and axial compressive loads simultaneously to force a tubular blank to conform to. Metal forming is a primary manufacturing process that includes drawing, forging, rolling, and bending. For most metal forming processes, when the total strain is plotted against the homogeneous deformation, the former increases at a higher rate than would be expected for an efficient forming process.
Unfortunately, poor drawability of some materials makes it impossible to use classical forming methods. Merklein m, allwood jm, behrens ba, brosius a, hagenah h, kuzman k, mori k, tekkaya ae, weckenmann a 2012 bulk forming of sheet. Unconventional forming process need for unconventional machining process harder and difficult to machine materials, can be machined easily and precisely. Pdf mechatronic contouring system for unconventional. For almost all sheet metal components, blankingpunching or cutting off is the very first process. The fundamental of metal forming theory, the theories of processes of rolling, forging and stamping as well as draw ing and pressing extrusion have been given. The workpiece is reshaped by high intensity pulsed magnetic fields that induce a current in the workpiece and a corresponding repulsive magnetic field, rapidly repelling portions of the workpiece. Comparison of metal forming processescomparison of metal forming processes 34. Nonconventional metal forming processes are also known as nontraditional forming. Metal forming processes, also known as mechanical working processes, are primary shaping processes in which a mass of metal or alloy is subjected to mechanical forces. High energy rate forming processes such as explosive forming, electrohydraulic forming etc are discussed in this section. Forming by liquids belong to nonconventional forming methods, for which.
Metal removal technique by using powerful electric spark work material electrically conductive materials. Zoha nasir assistant professor jit, barabanki slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Department of mechanical engineering ubmc303 manufacturing technology i question bank unit 4 sheet metal processes part a 2 marks 1. One of its first modern uses was in the early 1900s to make the tungsten filaments for incandescent light bulbs. Buy theory of plasticity and metal forming processes by dr. Unconventional metal forming processes 12312016 jit 1 unit v by. Cafp 2008 special metal casting and forming processes hot working forming processes are commonly hot working and cold working operations. Download theory of plasticity and metal forming processes by.
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