Extended Syllabus
(Fall semester, 2014)
Course
Name
Forming Process Design
Credit
Theory ( 2.0 ), Experiment ( 0.0 ),
Design( 1.0 )
Class
Hour
Course
No.
Targeting
MEE3024
Junior, Senior
Classroom AS311
Wed, Fri, 15:00~16:15
Homepage:
http://nsmlab.sogang.ac.kr/
Prof. : Joseph Domblesky
E-mail: joe.domblesky@marquette.edu Tel : 02-705-7999
Office : K326
Office Hour : Mon, Wed, Fri, 10:30~12:00
Ⅰ. Course Overview
1. Introduction
As Korea’s manufacturing companies must maintain global competitiveness by improving its
industrial capital, it is crucial to educate manpower and develop human capital to maintain
and increase such strength. It is also necessary to ensure development of technologies that
enable “manufacturing for design” and will attract consumers’ aesthetics. This requires
sophisticated training rather than simply improving the capability of products.
Processing and forming is more than just processes, students also must understand the
behaviors of materials to be formed to achieve a value added defect-free part in molds and
dies. Both simplified and the advanced analysis methods will be explained and used to
predict material and product behavior. The simplified method will be a sound tool to obtain
overview of specific forming processes, while the advanced method like the finite element
method will give detailed numbers and distributions of physical variables that is necessary
for process design. In the course, students are encouraged to understand and to be trained to
use the analysis tools which can be applied for process design. It is expected that students are
well equipped with the capability to utilize design tools based on the sound knowledge of
process analysis and ultimately to play key roles in research and development of value added
products.
2. Prerequisites
(1) Solid Mechanics: understanding stress and strains, Mohr’s circle, stress analysis for simple
2D cases, Beam theory
(2) Design and materials: types of engineering materials like metals, polymers, composites,
and ceramics. Solidification of metals, Mechanical properties, Strengthening mechanism,
Structures and characteristics of polymers and ceramics.
(3) Manufacturing processes
(4) Introduction of Fluid dynamics and Heat transfer
3. Class composition (%)
1
lecture
60 %
4. Evaluation
Mid term
35 %
discussion
0%
experiment
25 %
practice
0%
presentation
0%
other
15 %
(%)
Final
term
35 %
Quiz
0%
Presentation Projects
0%
10 %
Home
works
5%
attendan
ce
5%
other
10 %
Ⅱ. Course Objectives
It is to understand mechanical principles and process parameters of forming processes of
metals and polymers. The processes include forging, rolling, extrusion, drawing, sheet
forming, and injection molding. Students are trained to build up models for process and
materials, the simple analysis method, and the advanced computer simulation technique to be
a sound base of CAE. Students are encouraged to apply the results of process analysis to
process design including mold and die design for net-shape manufacturing. Students are also
intended to acquire skills for material testing, material behavior modeling, and how to
determine equivalent material properties that are indispensable to modern CAE technology.
Ⅲ. Course Format
This course is offered by lecture, experiment, practice, and short projects.
1. Lecture
Lecture is delivered by
(1) Voice + microphone/speaker
(2) Power point lecture note: it is distributed to students via home page. It can be utilized as a
workbook.
(3) Writing on Tablet PC and beam projector: deliver the course contents more clearly; I will
add notes directly on Tablet PC monitor showing the power point lecture note.
2. Homework combined with experiments and short projects
This course offers fundamental experiments like tensile test and ring/cylinder compression to
evaluate material properties. It also offers forming practice using model materials and CAE
practice using ABAQUS and Deform. The results of experiments and practice should be
summarized in reports.
Ⅳ. Course Requirements and Grading Criteria
2
1. Midterm and Final exams during scheduled exam weeks
2. Homework: assigned periodically from text and handout problems.
3. Short projects: selected processes including forging, extrusion (or rolling), sheet
forming, and injection molding. It should be specially noted that it is individually not
team-overall graded depending on the individual contributions. In other words, not
all the team members have the same grade.
4. Attendance: 1.5% of total grade will be deducted per absence. One late attendance is
equivalent to 1/3 of absence or 0.5% deduction.
Ⅴ. Course Policies
1. Rule for homework submission: it is to encourage early preparation, early
submission gets extra points. Late submission is not acceptable.
2. Supports for handicapped students:
(1) Guaranteed seat selection, individualized lecture note, and tutoring,
(2) Quiz and final term can be taken in a designated place and time can be extended,
(3) Other necessary supports are available,
(4) But, late submission of homework is not acceptable.
3. All the materials and notices are offered via web site.
4. If any cheating are found in written test and reports, the individual students will be
reported to the administrative office and get F grade.
5. It is encouraged to be counseled via e-mail.
6. TA: Lim, Hyun-Ji (guswl555@daum.net)
Ⅵ. Materials and References
<textbook>
1) lecture notes
2) Manufacturing Processes for Engineering Materials, Kalpakjian and Schmid (English
or Korean version)
<references>
1) User’s manuals for ABAQUS and Deform.
2) Naksoo Kim and Hyungjong Kim, <Metal forming and its analysis>, Munun-dang,
2002 (in Korean).
Ⅶ. Course Schedule
(* may be modified later)
Goal
Week 1
Contents
Students will understand concepts, classification, and overall
characteristics of forming processes. It is also to recognize the
importance of forming with respect to maintaining national
economic competitiveness and quality of life.
1. development of products by forming processes
2. role of virtual manufacturing technology
3. classification of forming processes
3
4. analysis scope and symbols
5. properties and structure of materials in forming
processes
Course format
Material
Assignment
Goal
Lecture and discussion
1) textbook, 2) lecture notes
Read Chapter 3 - Structure and Manufacturing Properties of
Metals
It is to understand mechanical properties such as yield condition
and stress-strain curve. Students can explain the yield
mechanism of metals and effects like temperature rise and
microstructural changes due to plastic deformation. Students
explain the constitutive laws of elastic deformation and plastic
deformation, respectively.
1.
2.
3.
4.
Week 2
Contents
Course format
Material
Assignment
Goal
Week 3
Contents
Introduction to material deformation
Strain, stress, and yielding
Parameters and conditions for yielding
Metals yield criteria
(1) von Mises yield criterion
(2) Tresca yield criterion
(3) Yield surfaces
5. Effective stress and strain, flow stress, work-hardening
6. Constitutive laws
(1) Generalized Hooke’s law
(2) Flow rule
7. Deformation heating
Lecture, discussion, and experiment
textbook, lecture notes, manual for cold compression experiment
Read Sections 2.1-2.4, 2.10-2.12
Perform cylinder compression testing experiment
Students explain instability due to deformation and the
relationship of residual stress-fatigue-product reliability.
Understand use of the slab method and the upper bound
technique as predictive tools.
1. Necking and instability
2. Analysis methods for forming processes
3. Slab method
4. Upper bound technique
(1) upper bound theorem
(2) velocity discontinuity
4
(3) procedures for analysis
Course format
Material
Assignment
Goal
Contents
Week 4
Course format
Material
Assignment
Goal
Contents
Week 5
Course format
Material
Assignment
Goal
Week 6
Contents
Lecture and discussion
Textbook and lecture notes
Submit report for compression testing
It is to understand principle of the finite element method.
Students explain heat generation qualitatively, friction, and wear
due to plastic deformation.
1. The finite element formulation
2. Analysis for heat transfer
3. Friction, wear, and lubrication
4. Mold and die, forming equipment
Lecture, discussion, and experiment
textbook, lecture notes, manual for using DEFORM software
Read Section 4.4
Attend FE demonstration using DEFORM FE software
Simulate cold extrusion using DEFORM software
It is to understand major forging parameters and to analyze
forging process.
1. Introducing forging process
2. Open die forging
3. Closed die forging
4. Incremental forming
5. Extrusion forging
6. Analysis for hot closed die forging
Lecture, discussion, and experiment
textbook, lecture notes, manual for die stress analysis
Read Sections 6.1-6.2
Submit report on cold extrusion simulation
Attend Deform 2D demonstration for performing die stress
analysis
Students understand design procedures employed in closed die
forging.
1. Introducing preforming process
2. Quality of forged products: defects, grain flow line, and
forgeability
3. Forging die design
5
4. Procedures for preform design
Course format
Material
Assignment
Goal
Contents
Week 7
Course format
Material
Assignment
Lecture, discussion,
Textbook and lecture notes
Submit report for cold extrusion die stress analysis
Students understand the extrusion process and can explain
process parameters.
1. Introducing extrusion process
2. Simple method to evaluate extrusion load: process
parameters, forward extrusion, backward extrusion, load
evaluation using model material
3. Analysis for forward extrusion
4. Analysis for backward extrusion
5. Effects of work-hardening and strain-rate
6. Extrusion defects
Lecture and discussion
textbook, lecture notes, manuals for plasticine extrusion
experiment
Read Section 6.4
Plasticine extrusion experiment
Goal
Contents
Week 8
(midterm period)
Course format
Material
Assignment
Goal
Contents
Week 9
Course format
Material
Students can explain the characteristics, limits, and optimal die
angle of drawing process.
1. Introducing drawing process
2. Wire drawing
3. Optimization and limit of drawing process
4. Tube drawing
Lecture, discussion, and experiment
textbook, lecture notes, manual for metal forming friction
experiment and simulation
6
Assignment
Goal
Contents
Week
10
Course format
Material
Assignment
Goal
Contents
Week 11
Course format
Material
Assignment
Goal
Week
12
Contents
Read Section 6.5
Friction in metal forming (compression and simulation)
experiment
Submit report of extrusion experiment using plasticine model
material
Students understand rolling processes and can analyze it by
using simple closed form solutions and the slab method.
1. Types of rolling processes
2. Mechanics of material deformation in rolling process
3. Analysis of cold flat rolling
4. Analysis of hot rolling
5. Rolling defects
6. Shape rolling
Lecture, discussion, and analysis project
Textbook and lecture notes
Read Section 6.3
Submit friction in metal forming report
Do Rolling handout problems
Students explain formability, forming limit diagram, and
springback of sheet metals.
1. Fundamentals of sheet forming process: anisotropy,
formability, dent resistance
2. Yield function of anisotropy
3. Forming limit
4. Springback
Lecture, discussion, and experiment
1) textbook, 2) lecture notes, 3) manuals for ABAQUS and
cup drawing experiment
Read Sections 7.1-7.2
Demonstration using ABAQUS software code
Sheet metal forming simulation using ABAQUS software code
Students understand mechanisms of shearing and bending of
sheet materials. Students can analyze and design simple sheet
metal forming process.
1. Shearing: process parameters, shearing load, and
shearing dies.
2. Bending: minimum bending radius, compensation for
springback, bending load
3. Roll forming
4. Spinning
7
Course format
Material
Assignment
Goal
Contents
Week
13
Course format
Material
Assignment
Goal
Contents
Week
14
Course format
Material
Assignment
Goal
Week
15
Contents
Course format
Lecture, discussion, and project
textbook, lecture notes
Read Sections 7.3-7.5, 7.7-7.10
Submit report on ABAQUS sheet metal simulation
Do shearing design problem
Students understand the characteristics and limits of deep
drawing process and can analyze the process. Students explain
the forming limit of sheet material quantitatively.
1. Introducing sheet forming processes
2. Deep drawing process
3. Hydroforming process
4. Other sheet forming
Lecture, discussion, and a term project
textbook, lecture notes
Read Section 7.6
Submit shearing die design and analysis
Students understand and explain the structure and characteristics
of polymer. It is to understand the characteristics of composite
materials. Students can explain major process parameters in
polymer processing.
1. Introducing injection molding processes
2. Structure and characteristics of polymer
3. Classification of polymers and composites
4. Extrusion mechanics in extruding barrel
Lecture, discussion, and experiment
textbook, lecture notes, manual for MOLDFLOW and injection
molding experiment
Read Chapter 10
Demonstration of Moldflow CAE software
Simulate injection molding process using MOLDFLOW
Students can perform CAE of injection molding. They also
understand and analyze the post deformation after ejection.
1. CAE of injection molding processes
2. Analysis of post deformation of polymer products
3. Powder injection molding
Lecture and discussion
8
Material
Assignment
textbook, lecture notes
Submit report of injection molding simulation
Goal
Contents
Week
16
Course format
(evaluation via final term)
(written test)
Material
Assignment
Ⅷ. Special Accommodations
9