Selected Chapters of Metal-forming (FSI-HVT)

Academic year 2022/2023
Supervisor: Ing. Eva Peterková, Ph.D.  
Supervising institute: ÚST all courses guaranted by this institute
Teaching language: Czech
Aims of the course unit:
The objective of the course is to provide the students with the necessary knowledge and information from the field of metal forming that they could not acquire in the course of studying special subjects so far.
Learning outcomes and competences:
Students majoring in metal forming will have an overview of the methods and selected calculation models for dimensioning metal-forming tools. They will be made familiar with the theory and technologies of high strain-rate metal-forming methods, as well as with the latest knowledge in the field.
Prerequisites:
Successful completion of the course is conditional on the knowledge of applied mathematics and physics, materials science, elasticity, strength, plasticity, and examination of the subject the theory of metal-forming.
Course contents:

The course provides information from the areas of strength design and dimensioning of metal-forming tools. The second part includes the theory and technology of metal-forming by high strain rates and energies. This specialized instruction includes, among other things, combined reforging, impact indentation, bulk renovation of machine parts and tools, high-rate die forging, explosive, electrohydraulic and electromagnetic metal forming. Also dealt with are cavity shooting, application of explosion energy, dynamic compacting of metallic and non-metallic powders. Modelling of high strain-rate processes is demonstrated. In the third part, students are confronted with the latest results of research.
Teaching methods and criteria:
The course is taught through lectures explaining the basic principles and theory of the discipline. Teaching is suplemented by practical laboratory work.
Assesment methods and criteria linked to learning outcomes:
The course-unit credit is awarded on condition of having attended all laboratory exercises and worked out partial written programs.
The exam has a written and an oral part, based on a set of lot-drawn questions.
Controlled participation in lessons:
Attendance in lectures is recommended.
Attendance in exercises is compulsory.
The attendance to the seminar is regularly checked and the participation in the lesson is recorded.
Absence from laboratory exercises is compensated for via make-up topics of exercises and consultations.
Type of course unit:
    Lecture  13 × 2 hrs. optionally                  
    Laboratory exercise  13 × 2 hrs. compulsory                  
Course curriculum:
    Lecture

  1. Limit states of forming processes, limit diagrams of plastic deformation.

  2. Limit states of stress, conditions of free and minimum security.

  3. Analysis of damage to metal forming tools, problems of durability, service life and reliability.

  4. Analytical procedures in strength design of forming tools.

  5. Approximate stress-strain curves in the calculation models.

  6. Application of the FEM in analysis of large plastic deformation.

  7. Application of the FEM in the analysis of stress and deformation tools.

  8. Theory and technology of metal forming in conditions of real strain rates.

  9. Significant factors of high-speed deformation, define of relations.

  10. Influence of strain-rate to the deformation resistance, the critical impact speed.

  11. Evaluation of dynamic mechanical properties under impact – Taylor Anvil Test-TAT.

  12. Evaluation of dynamic mechanical properties of materials by the Split Hopkinson Pressure Bar Test-SHPBT.

  13. Review of forming methods using high-speed deformation.
    Laboratory exercise

  1. Limit states of stress during upsetting and extrusion, conditions of free and minimum security.

  2. Procedure in dimensioning complex dies by the MPIN method.

  3. Procedure in dimensioning complex dies by the MPIN method.

  4. Solving the contact problem by the FEM program, punch and die application, comparison with conventional solution. 

  5. Solving the contact problem by the FEM program, punch and die application, comparison with conventional solution.

  6. Simulation of the forming process in real viscoplastic conditions, demonstration on FORM2D.

  7. Evaluation of mechanical properties at high strain rates.

  8. Determining mechanical properties by the method of Hopkinson bar.

  9. Evaluation of dynamic mechanical properties under impact, using the Taylor Anvil Test.

  10. Structural analyses of experimental specimens and real products, explosion forming.

  11. Simulation of metal-forming processes in conditions of high strain-rates.

  12. Calculation of the dependence of stress function on deformation, temperature and strain rate.

  13. Conclusion of exercises, discussion of reports. Course-unit credit.
Literature - fundamental:
1. MEYERS, Marc A. Dynamic behavior of materials. New York: John Wiley and Sons., c1994. 668 p. ISBN 0-471-58262-X
2. LANGE, Kurt. Handbook of metal forming. New York: McGraw-Hill, c1985, 900 p. ISBN 00-703-6285-8.
3. MIELNIK, Edward M. Metalworking science and engineering. New York: McGraw-Hill, c1991, 976 p. McGraw-Hill. ISBN 00-704-1904-3.
4. ZHERNOKLETOV, Mikhail V.; GLUSHAK, Boris L.; ANDERSON, William W.; CHERNE, Frank J.  and ZOCHER, Marvin A.. Material properties under intensive dynamic loading. New York: Springer, c2006. 422 p. ISBN 978-3-540-36844-1.
Literature - recommended:
1. FOREJT, Milan; KREJČÍ, Jan a BUCHAR, Jaroslav. Teorie a technologie tváření vysokými deformačními rychlostmi a energiemi: Vybrané statě z tváření. 2. vyd. Brno: VUT FSI. 1994. Sylabus. FRVŠ
2. Forejt, Milan. Proceedings of International Conference FORM´95,´97, ´98, 2000, 2002, 2004, 2006, 2008, 2010.
3. ASM International. Metals Handbook Ninth Edition: Forming and Forging. 1st ed. Metals Park Ohio: ASM International. 1988. vol. 14. ISBN 0-87170-007-7.
The study programmes with the given course:
Programme Study form Branch Spec. Final classification   Course-unit credits     Obligation     Level     Year     Semester  
CŽV full-time study CZV Bases of Mechanical Engineering -- Cr,Ex 4 Compulsory-optional 1 1 S
N-STG-P full-time study STG Manufacturing Technology -- Cr,Ex 4 Compulsory-optional 2 2 S