Theory of Metal Forming (MFGE542) Course Detail

Course Name Course Code Season Lecture Hours Application Hours Lab Hours Credit ECTS
Theory of Metal Forming MFGE542 3 0 0 3 5
Pre-requisite Course(s)
N/A
Course Language English
Course Type N/A
Course Level Natural & Applied Sciences Master's Degree
Mode of Delivery Face To Face
Learning and Teaching Strategies Lecture, Demonstration, Drill and Practice, Problem Solving.
Course Coordinator
Course Lecturer(s)
  • Asst. Prof. Dr. Celalettin Karadoğan
Course Assistants
Course Objectives This course aims to give the students the in-depth understanding of mechanics of metal forming .
Course Learning Outcomes The students who succeeded in this course;
  • Students will learn the basics of plasticity
  • Students will understand the fundamentals of metal working
  • Students will attain proficiency in basic metal forming techniques, forging, extrusion, drawing and rolling.
Course Content Elements of the theory of plasticity, fundamentals of metal working, forging process, rolling process, extrusion process, drawing of rods, wires and tubes, sheet metal forming process, high energy rate forming.

Weekly Subjects and Releated Preparation Studies

Week Subjects Preparation
1 Chapter 1: ELEMENTS OF THE THEORY OF PLASTICITY: Flow curves, True stress and strain, yield criteria for ductile metals, Von Mise’s criterion, Tresca criterion.
2 Chapter 2:FUNDAMENTALS OF METAL WORKING: Classification of forming processes, Mechanics of Metal working – slab method, flow stress determination, Temperature in Metal working, Hot working, Cold working, Warm working, strain - rate effects, metallurgical structure, friction and Lubrication.
3 Chapter 3: FORGING PROCESS: Classification of forging operation, forging equipment, forging strain, open die forging – closed die forging, die forging load forging defects.
4 Chapter 3: FORGING PROCESS: Classification of forging operation, forging equipment, forging strain, open die forging – closed die forging, die forging load forging defects.
5 Chapter 4: ROLLING OF METALS: Classification of rolling mills, hot and cold rolling forces and geometrical relationships in rolling, simplified analysis of rolling load, defects in rolled products, theories of cold and hot rolling, calculation torque and power required.
6 Chapter 4: ROLLING OF METALS: Classification of rolling mills, hot and cold rolling forces and geometrical relationships in rolling, simplified analysis of rolling load, defects in rolled products, theories of cold and hot rolling, calculation torque and power required.
7 Chapter 5: EXTRUSION: Classification, equipments used, hot extrusion, deformation, lubrication and defects in extrusion, analysis of extrusion processes, hydrostatic extrusion, tube extrusion, production of seamless pipe and tubing.
8 Chapter 5: EXTRUSION: Classification, equipments used, hot extrusion, deformation, lubrication and defects in extrusion, analysis of extrusion processes, hydrostatic extrusion, tube extrusion, production of seamless pipe and tubing.
9 Chapter 6: DRAWING OF RODS, WIRES AND TUBES: Rod and wire drawing process, drawing dies, analysis of wire drawing, Tandem drawing process, residual stress in rod, wire and tube drawing. Defects in drawing, tube drawing.
10 Chapter 6: DRAWING OF RODS, WIRES AND TUBES: Rod and wire drawing process, drawing dies, analysis of wire drawing, Tandem drawing process, residual stress in rod, wire and tube drawing. Defects in drawing, tube drawing.
11 Chapter 7: SHEET METAL FORMING PROCESS: Introduction, Forming methods, shearing, blanking, punching, bending, spring back, elimination of spring back, spinning, deep drawing stretch forming, redrawing, reverse drawing, defects in drawing, factors affecting drawability ration.
12 Chapter 7: SHEET METAL FORMING PROCESS: Introduction, Forming methods, shearing, blanking, punching, bending, spring back, elimination of spring back, spinning, deep drawing stretch forming, redrawing, reverse drawing, defects in drawing, factors affecting drawability ration.
13 Chapter 8: HIGH ENERGY RATE FORMING (HERF): Introduction to HERF, Process advantages, explosive forming electro discharge forming and electromagnetic forming, Rubber forming.
14 Chapter 8: HIGH ENERGY RATE FORMING (HERF): Introduction to HERF, Process advantages, explosive forming electro discharge forming and electromagnetic forming, Rubber forming.
15 Final Examination Period
16 Final Examination Period

Sources

Course Book 1. Mechanical Metallurgy - Dieter. G. E - McGraw Hill, 2001
Other Sources 2. Principle of Industrial metal working process–Rowe Edward Arnold, London, CBS Publishers - 2002.
3. Mikell P. Groover, Fundamentals of Modern Manufacturing, Materials, Processes and Systems.

Evaluation System

Requirements Number Percentage of Grade
Attendance/Participation - -
Laboratory - -
Application - -
Field Work - -
Special Course Internship - -
Quizzes/Studio Critics - -
Homework Assignments 4 20
Presentation - -
Project - -
Report - -
Seminar - -
Midterms Exams/Midterms Jury 2 50
Final Exam/Final Jury 1 30
Toplam 7 100
Percentage of Semester Work 70
Percentage of Final Work 30
Total 100

Course Category

Core Courses X
Major Area Courses
Supportive Courses
Media and Managment Skills Courses
Transferable Skill Courses

The Relation Between Course Learning Competencies and Program Qualifications

# Program Qualifications / Competencies Level of Contribution
1 2 3 4 5
1 Ability to expand and get in-depth information with scientific researches in the field of mechanical engineering, evaluate information, review and implement.
2 Have comprehensive knowledge about current techniques and methods and their limitations in Mechanical engineering.
3 To complete and apply knowledge by using scientific methods using uncertain, limited or incomplete data; use information from different disciplines.
4 Being aware of the new and developing practices of Mechanical Engineering and being able to examine and learn when needed.
5 Ability to define and formulate problems related to Mechanical Engineering and develop methods for solving and apply innovative methods in solutions.
6 Ability to develop new and/or original ideas and methods; design complex systems or processes and develop innovative/alternative solutions in the designs.
7 Ability to design and apply theoretical, experimental and modeling based researches; analyze and solve complex problems encountered in this process.
8 Work effectively in disciplinary and multi-disciplinary teams, lead leadership in such teams and develop solution approaches in complex situations; work independently and take responsibility.
9 To establish oral and written communication by using a foreign language at least at the level of European Language Portfolio B2 General Level.
10 Ability to convey the process and results of their studies systematically and clearly in written and oral form in national and international environments.
11 To know the social, environmental, health, security, law dimensions, project management and business life applications of engineering applications and to be aware of the constraints of their engineering applications.
12 Ability to observe social, scientific and ethical values in the stages of data collection, interpretation and announcement and in all professional activities.

ECTS/Workload Table

Activities Number Duration (Hours) Total Workload
Course Hours (Including Exam Week: 16 x Total Hours)
Laboratory
Application 16 2 32
Special Course Internship
Field Work
Study Hours Out of Class 16 6 96
Presentation/Seminar Prepration
Project
Report
Homework Assignments 4 8 32
Quizzes/Studio Critics
Prepration of Midterm Exams/Midterm Jury 2 7 14
Prepration of Final Exams/Final Jury 1 15 15
Total Workload 189