Course Specifications
Relevant Programme
B.Sc. in Engineering
Department offers the programme
Faculty of Engineering (Production
Engineering and Mechanical Design)
Department offers the course
ٍ
Department of Metallurgy-Faculty of
Engineering- Cairo University*
Production Engineering and Mechanical Design
Scholar year
Metal Forming 3rd Year Production
Engineering and Mechanical Design / First Semester
Date of specification approval
2006
*Instructor:
Dr Mahmoud M. Tash
e-mail: mahmoud_tash1@yahoo.com
A- Basic Information
Title: Theory Metal Forming
Code: MPD3117
Credit Hours: Lecture: 3 Tutorial and Practical:
3
Total:
6
B- Professional Information
1 – Aims
1. Learn the basics of metal forming processes and the yielding criteria
2. Conduct simple mechanical analysis calculations on work piece and calculate the
necessary loads, using the stress equations he learns from the course of "Theory
of Elasticity and Plasticity".
3. Correlate the various metal working parameters (stress, temperature, and strain
rate) to basic metallurgical and mechanical properties.
4. know the mechanical and metallurgical aspect in plasticity
5. Compare the cold and hot forming processes
6. Understand the role of friction and tribology in metal forming
7. Conduct simple mechanical analysis calculations on work piece and calculate the
necessary loads by different theorem (Ideal work-Strip method or force
equilibrium-upper bound theorem-slip line fields-FEM).
8. Conduct simple forging load calculations.
9. learn certain metal forming process (forging, extrusion, drawing and rolling)
2 – Intended Learning Outcomes (ILOs)
a-Knowledge and Understanding:
a.1Technology of metal forming processes.
a.2 Mechanics of metal working.
a.3 Metallurgy of metal working.
a.4 Technology of rolling and sheet metal forming processes.
a.5 Mechanics of rolling.
b-Intellectual Skills
b.1 Calculation of loads necessary for a certain metal forming process.
b.2 Identifying suitable metal forming operation for some products.
b.3 Calculation of loads necessary for rolling.
c- Professional and Practical Skills
c1- Learning how are parts manufactured.
c2- Selection of proper metal working process for different parts.
d- General and Transferable Skills
d1- Working in a team.
d2- Writing a technical report.
d3- Presenting a report.
3- Contents
Lecture Topic Outline
No. of hours
Week
Topics
Lect.
Tutorial
1
Introduction: Classification of forming processes, Review on 3
some concepts related to metal forming: true stress-strain curve,
yielding criteria., Solved examples on calculation of true and
engineering strains
3
2
Mechanics of metalworking: slab method, uniform deformation
energy method. Solved examples on calculation of true and
engineering strains and application of yielding phenomena.
3
3
Friction and lubrication in metal working, the effect of friction
on load calculations, sliding vs sticking friction. Deriving the
equations describing load requirements taking friction into
consideration.
3
4
Metallurgical aspect of metal working: Metallurgical effects in
metal working: (static and dynamic) recovery and
recrystallization.
3
5
Metallurgical aspect of metal working: hot and cold working.
Temperature-pressure-strain rate effect on amount of
deformation.
6
Mid-term Exam
3
3
7
Forging Process, calculation of forging load.
3
3
8
Extrusion Process, direct and indirect extrusion, problems.
3
3
9
Methods of solving problems in metal forming: forging,
3
3
3
3
3
3
3
extrusion and drawing
3
10
Conduct simple mechanical analysis calculations on work piece
and calculate the necessary loads by Ideal work and Strip method
or force equilibrium theorem.
11
Conduct simple mechanical analysis calculations on work piece
and calculate the necessary loads by upper bound theorem.
3
12
Conduct simple mechanical analysis calculations on work piece
and calculate the necessary loads by slip line field theory .
3
13
forging, extrusion, rolling and drawing: basics.
3
3
14
forging, extrusion, rolling and drawing: processes
3
3
3
3
3
4– Teaching and Learning Methods
4.1- Lectures: Blackboard, Overhead Transparencies
5- Student Assessment
Homework to assess problem solving abilities. Mid-term to assess understanding and
versatility. Oral Discussions to assess understanding and ability to present data. Final
Exam to assess overall course assimilation.
Year Work
Item
#Points%
Attendance and Pop Quizzes
Homework assignments
One midterm exams
Final Examination
1
15
10
35
60
90
Totals__
150
6- List of References
6.1- Course Notes
6.2- Essential Books (Text Books)
1- Mechanical Metallurgy; G. E. Dieter, Mc. Graw-Hill Book Company, 1988. (Part
4, ch15-20).
2- Mechanical Working of Metals: Theory and Practice; Pergamon International
Library.
6.3- Periodicals, Web Sites, … etc