Theory of Metal-forming (FSI-HTA)

Complex engineering solutions of the technological processes of metal-forming are based on the theory of plasticity and theory of metal-forming with systems of computer support. The content of the course starts from selected chapters of the physical essence of plastic strain, formability of metals and alloys, fundamentals of mathematical theory of plasticity, and experimental/analytical methods for the theoretical solution of metal-forming processes. The course provides the basic knowledge of and skills in mathematically describing metal-forming processes while applying the physical, chemical, mechanical and thermodynamic principles of the transition of metallic bodies from elastic into plastic state in the course of their plastic deformation into the required shape. The course also addresses the problem of determining the loading of metal-forming tools and machines, carries out analyses of deformation, establishes critical strain values and offers an introduction to computer-aided modelling of metal-forming processes.

1. Physical substance of plastic deformation. Formability of metals and alloys.
2. Resistance to deformation, effect of basic parameters. Deformation work and force.
3. Summary of the fundamentals of mathematical theory of plasticity. Partial theories.
4. Conditions of the appearance of plastic deformation. Analysis of the deformation process.
5. Analytical and analytical-experimental methods for solving metal-forming processes.
6. Upsetting between parallel planes, the Siebel and the Unksov solutions.
7. Forward extrusion, stress and strain analysis.
8. Backward extrusion, solution after Dipper, Sachs and Siebel.
9. Die forging, solution after Tomlen, Gubkin, Gelei and Storozhev
10. Bending of thin bars and wide bands.
11. Deep drawing, stress and strain, calculation after Sachs and Sofman.
12. Method of resistance to deformation. Theory of small elastic-plastic deformations.
13. State of stress in free and closed shear and in precise shearing.

1. Problems of the physical substance of plastic deformation, demonstrations, report.
2.Evaluation of the parameters of deformation, deformation rate, report.
3.Calculation of main and effective stress, graphic interpretation, report.
4.Evaluation of resistance to deformation curves obtained from experiments.
5.Calculation of resistance to deformation and forces in upsetting, report.
6.Stress and forces in forward extrusion, report.
7.Stress and forces in backward extrusion, report.
8.Die forging, calculation of forging forces, report.
9.Calculation of bending forces and springing-back, report.
10.Stress, forces and number of drawing operations, report.
11.Evaluation of stress and strain on a drawn part, report.
12.Stress in current and precise shearing, report.
13.Conclusion of exercises, discussion of reports. Course-unit credit.