MFM Lect 1

Metal Forming & Machining

MF C314

Instructor-in-charge:

Dr. T. C. Bera

Room No: 2226

Practical Instructor:

Mr. Navneet Khanna

Brief about Course Contents

� Introduction to Metal Forming

� Material behavior in Metal Forming

� Various metal forming processes

� Analysis of various metal forming processes

� Introduction to Machining� Introduction to Machining

� General machining processes

� Materials and cutting tool geometry

� Mechanics of metal cutting

� Thermal aspects and cutting fluids

� Tool wear, tool life and machinability

� Economics of machining

Scope and Objectives of the course

� The course aims at developing the theoretical andpractical knowledge base about Metal Forming &Machining.

� It helps to analyze these two broad versatile� It helps to analyze these two broad versatileproduction processes and to realize their importancein manufacturing.

� At the end of the semester student will know whereand how they will implement forming and/ormachining to manufacture desired products.

Text Book

i)B.L. Juneja, “Fundamentals of Metal Forming

Processes”, New Age International Publications,Delhi. 2010.

ii)B.L. Juneja, G.S. Sekhon and Nitin Seth,ii)B.L. Juneja, G.S. Sekhon and Nitin Seth,“Fundamentals of Metal Cutting and MachineTools”, New Age International Publications, Delhi.2010

Reference Books� i) A. Ghosh and A. K. Mallik, "Manufacturing Science",

East-West Press Private Limited

� ii) S. Kalpakjian and S.R. Schmid, “Manufacturing Processes for Engineering Materials", Pearson Publications, Fifth Edition

� iii) William Hosford and Caddel, “Metal Forming � iii) William Hosford and Caddel, “Metal Forming Mechanics and Metallurgy", Cambridge University press.

� iv) Milton C. Shaw, "Metal Cutting Principles", Oxford University Press, II Edition.

� v) A. Bhattacharyya, “ Metal Cutting Theory and Practice", New Central Book Agency.

� vi) A. B. Chattopadhyay, "Machining and Machine Tools", Wiley India, 2011.

Evaluation Scheme & Exam Schedule

Component Duration % Weightage Date & Time Remarks

Mid-Sem Test

90 min 30 03/10/12, 4.00-5.00 PM

Open Book

Surprise Quiz

10 Closed BookQuiz

Lab Exp. / Project

20 Viva Voce

CompreExam

3 hrs 40 14/12/12AN

Closed Book

Chamber Consultation Hour

� 5.00-6.00 PM, Room-2226

Primary Manufacturing Processes� Casting

� Forming

� Machining

� Joining

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• First Semester - Metal Forming & Machining

• Second Semester - Casting & Welding

METAL FORMING

*Metals may be formed into useful shapes in two basic ways:

1. By plastic deformation processes in which the volume and

mass of metal are conserved and the metal is displaced from

one location to another.

2. By metal removal or machining processes in which material is

removed in order to give it the required shape.

*Metal forming processes may be classified into only a few

categories on the basis of the type of forces applied to the

work-piece as it is formed into shape.

� Direct-compression-type processes

� Indirect-compression processes

� Tension type processes� Tension type processes

� Bending processes

� Shearing processes

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Thread-rolling for bolts:

Rolled threads stronger than machined (and less expensive)

Kalpakjian

Introduction

� Addition to producing various external or internal round profiles,cutting operations can produce many other parts with more complex shapes

Fig:Typical parts and shapes produced with the machining process

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