Bmee304l Metal-Forming-And-Machining TH 1.0 70 Bmee304l

Agenda Item 65/46 - Annexure - 42
BMEE304L Metal Forming and Machining L T P C

3 0 0 3
Pre-requisite BMEE209L, BMEE209P Syllabus version
1.0
Course Objectives
1. To impart knowledge on the basic principles of metal forming theories and processes.
2. To give an insight on metal cutting theories, machine tools, and machining processes.
Course Outcomes
At the end of the course, the student will be able to
1. Develop the yield criterion and workability behaviors of materials.
2. Evaluate various bulk and sheet metal forming processes for different functional
requirements.
3. Demonstrate various machine tools and machining operations.
4. Analyse the mechanics of metal cutting processes.
5. Investigate the heat flow, tool life and tool wear during metal cutting process.
Module:1 Fundamentals of Metal Forming 6 hours
Stress-Strain relations in elastic and plastic deformation, stress tensor, yield criteria, yield
locus, octahedral shear stress and shear strains, invariants of stress strain, slip line field
theory plastic deformations of crystals temperature and strain rate dependence,
determination of flow stress- Slab analysis - Upper bound analysis - Slip line field analysis,
recrystallization, Deformation zone geometry - Numerical problems.
Module:2 Bulk Forming of Metals 7 hours

Forging: Classification of forging processes – Forging machines & equipment’s – Forging
pressure & load in open die forging and closed die forging – Friction hill – Die-design
parameters – Metal flowlines in forging – Forging defects – Residual stresses in forging -
Powder metallurgy forging.
Rolling: Classification of rolling processes – Types of rolling mills – Expression for rolling
load – Forces and geometrical relationships in rolling – Effect of front & back tension –
Friction hill – Defects in rolled product.
Extrusion: Classification of extrusion processes – Extrusion equipment’s – Deformation,
lubrication & defects – Extrusion of tubes & seamless pipes – Hydrostatic extrusion.
Drawing: Drawing equipment’s & Dies – Determination of drawing force & power –
Estimation of redundant work – Optimal cone angle & dead zone formation – Drawing
variables – Tube drawing processes.
Module:3 Sheet Metal Forming 5 hours
Conventional processes, Forces in circular cup drawing, Redrawing, drawing of tubes from
annular sheet dies, forming limit diagram, forming with hydrostatic pressure, explosive
forming, electrohydraulic forming, magnetic pulse forming, HERF, electromagnetic forming.
Forming limit criteria, defect in formed parts, principles and process parameters- Advantages
-Limitations and Applications.
Module:4 Machine Tools and Operations 6 hours
Generating motions of machine tools, Machines using single-point tools, operations and
process parameters – work and tool holding in engine lathe, horizontal-boring machine,
shaping machine, planning machine.
Machines using multipoint tools, operations and process parameters – drilling machine,
horizontal-milling machine, vertical-milling machine, broaching machine, taps and dies.
Machines using abrasive wheels, operations and process parameters – horizontal-spindle
surface-grinding machine, vertical-spindle surface-grinding machine, cylindrical-grinding
machine, internal-grinding machine, centerless grinding machines.
Cutting tool nomenclatures. Numerical expressions and simple problems on machining time
and material removal rate.
Module:5 Mechanics of Metal Cutting 7 hours
Orthogonal & oblique cutting, shear plane angle, shear stress and strain, principal chip
Proceedings of the 65th Academic Council (17.03.2022) 1288

Agenda Item 65/46 - Annexure - 42
types, theoretical determination of cutting forces – Ernst and Merchant’s theory, Lee and
Shaffer’s theory, Oxley’s theory. shear angle relation, friction in metal cutting, energy in
cutting process, Kronenberg relation and velocity relation, chip deviation and other effects on
cutting forces, stress on tool, stress distribution, Dynamometers for measuring forces in
turning, milling and drilling, numerical problems.
Module:6 Heat Flow in Metal Cutting and Tool Life 7 hours
Heat generation in metal cutting, heat at tool-work interface, heat at tool-chip interface, heat
in absence of flow zone, Temperature distribution in metal cutting, Measurement of cutting
temperature – Work-tool Thermocouple, direct thermocouple measurements, radiation
methods, evaluation of machinability.
Tool life, Taylor’s equation, tool failure, variables affecting the tool life causes of tool failures,
forms of wear in metal cutting, cutting tool materials, cutting Fluids, action of coolants and
lubricants, application of cutting fluids, surface roughness in machining and its
measurement, tool geometries for improved surface finish, economics of metal-cutting
operations.
Module:7 Gear generation and Unconventional machining 5 hours
methods
Gear generating principles - Gear Hobber - Gear finishing methods - Bevel gear generator.
Classification of unconventional machining process – Principle of AJM, WJM, USM, EDM,
ECM, LBM – Process characteristics – Applications.
Module:8 Contemporary Issues 2 hours
Total Lecture hours: 45 hours
Text Books
1. B.L. Juneja, Fundamentals of Metal Forming Processes, 2010, 2nd edition, New Age
International.
2. K.C. Jain, A.K. Chitale, Textbook of Production Engineering, 2014, PHI Learning Pvt.
Ltd.
Reference Books
1. George E Dieter, Mechanical Metallurgy, Tata McGraw Hill, 1988
2. Helmi A. Youssef, Hassan A. El-Hofy, Mahmoud H. Ahmed, Manufacturing
Technology: Materials, Processes, and Equipment, 2011, CRC Press, Taylor &
Francis Group
3. Heinz Tschaetsch, Metal Forming Practise, 2005, Springer Berlin Heidelberg New
York
4. Hosford W.F. Caddell R.M., Metal Forming – Mechanics and Metallurgy, 2011, 4th
edition, Cambridge University Press.
5. Geoffrey Boothroyd and Winston. A. Knight, Fundamentals of Machining and Machine
Tools, 2005, CRC Press, 3rd edition
6. Amitabha Battacharyya, Metal Cutting: Theory and Practice, 2011, New Central Book
Agency
7. Amitabha Ghosh and A.K. Mallik, Manufacturing Science, 2010, 2nd edition, East-West
Press.
8. Dixit U.S. and Ganesh Narayanan R, Metal Forming: Technology and Process
Modelling, 2013, McGraw-Hill Education, Noida
9. P.N. Rao, Manufacturing Technology: Metal Cutting and Machine Tools, 2018, Volume
2, 4th Edition, McGraw Hill Education.
10. Serope Kalpakjian, and Steven Schmid, Manufacturing Engineering and Technology,
2020, 8th edition, Pearson education.
11. P. L. B. Oxley, “The Mechanics of Machining”, 1989, Ellis Horwood Ltd.
Mode of Evaluation: CAT, Written assignment, Quiz, FAT.
Recommended by Board of Studies 09-03-2022
Approved by Academic Council No. 65 Date 17-03-2022
Proceedings of the 65th Academic Council (17.03.2022) 1289

Bmee304l Metal-Forming-And-Machining TH 1.0 70 Bmee304l

Uploaded by

Copyright:

Available Formats

Bmee304l Metal-Forming-And-Machining TH 1.0 70 Bmee304l

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Bmee304l Metal-Forming-And-Machining TH 1.0 70 Bmee304l

Uploaded by

Copyright:

Available Formats

Agenda Item 65/46 - Annexure - 42

BMEE304L Metal Forming and Machining L T P C

Module:2 Bulk Forming of Metals 7 hours

Proceedings of the 65th Academic Council (17.03.2022) 1288

Proceedings of the 65th Academic Council (17.03.2022) 1289

You might also like