Mechanics of Sheet Metal Forming

By Prof. R Ganesh Narayanan | IIT Guwahati

Learners enrolled: 184 | Exam registration: 2

ABOUT THE COURSE:

Sheet metal forming processes are useful in manufacturing components in automotive, aerospace, defense and stamping industries. The components are used in automobiles, household items, space equipment, defense equipment, and several others. There is a need to understand the mechanics part of the sheet forming processes such as deep drawing, stretch forming, bending, hydroforming, along with basic plasticity. This course will provide such details through theoretical analyses and numerical problems, along with basic concepts in metal forming. The first part of the course deals with several concepts in metal forming and plasticity, and the second part includes theoretical analyses of few sheet forming and tube forming operations. The course will be useful to design engineers, stamping engineers, manufacturing students and scholars, and academia. Through this course, participants will be able to apply basic concepts for modeling any manufacturing processes involving plastic deformation.

INTENDED AUDIENCE: Students (UG, PG), Researchers, Industry experts

PREREQUISITES: UG courses on Solid Mechanics

INDUSTRY SUPPORT:

Several industries such as Tata Motors, Tata Steel, Mahindra, Ashok Leyland, SAIL, BHEL, DRDO, IGCAR, BARC will recognize/value the online course.
Several stamping/sheet forming industries and their engineers will find the course useful.

Summary

Course Status :	Upcoming
Course Type :	Elective
Language for course content :	English
Duration :	8 weeks
Category :	Mechanical Engineering
Credit Points :	2
Level :	Undergraduate/Postgraduate
Start Date :	17 Feb 2025
End Date :	11 Apr 2025
Enrollment Ends :	17 Feb 2025
Exam Registration Ends :	24 Feb 2025
Exam Date :	04 May 2025 IST

Note: This exam date is subject to change based on seat availability. You can check final exam date on your hall ticket.

Page Visits

Course layout

Week 1: Description of Material properties

Lecture 1 : Introduction, Tensile test
Lecture 2:Effect of properties on forming and formability

Week 2: Sheet deformation processes
Lecture 3 : Uni-axial tension, general sheet forming processes, yielding
Lecture 4 : flow rule, work hardening hypothesis, work of plastic deformation, isotropic yield functions
Lecture 5 : isotropic yield functions, effective stress and strain

Week 3: Sheet deformation in plane stress
Lecture 6 : strain distributions, strain diagram, deformation modes
Lecture 7 : effective stress-strain laws, principal tensions

Week 4: Stamping analysis

Lecture 8 : 2-D modeling of stamping, stretch and draw ratios in stamping.

Week 5: Load instability and tearing

Lecture 9 : uniaxial tension of perfect strip and imperfect strip

Lecture 10 : tensile instability in stretching continuous sheet

Lecture 11 : tensile instability in stretching continuous sheet

Week 6: Sheet formability

Lecture 12 : Forming limit curve – concept and evaluation

Lecture 13 : FLC, formability tests, theoretical prediction, factors affecting FLC

Week 7: Sheet bending

Lecture 14 : Variables in bending a continuous sheet, equilibrium conditions

Lecture 15 : material models, bending without tension, springback prediction

Week 8: Cylindrical deep drawing & Stretching circular shells

Lecture 16 : Drawing the flange, cup height

Lecture 17 : redrawing cylindrical cups, wall ironing of deep drawn cups

Lecture 18 : Analysis of bulging with fluid pressure, stretching over punch

Lecture 19 : Hydroforming

Lecture 20 : Demonstration on sheet forming operations -stretching, bending, deep drawing.

Books and references

[1] D. Banabic, Sheet metal forming processes Constitutive modeling and numerical simulation, Springer-Verlag Berlin Heidelberg, 2010

[2] Z. Marciniak, J. L. Duncan, S. J. Hu, Mechanics of sheet metal forming, Elsevier,Butterworth-Heinemann, 2002

[3] R. H. Wagoner, J. L. Chenot, Fundamentals of metal forming, John Wiley and Sons, 1997

[4] W. F. Hosford, R. M. Caddell, Metal forming Mechanics and Metallurgy, Printice-Hall, 2007

[5] J. Chakrabarty, Theory of Plasticity, McGraw Hill, 1998.

[6] D. W. A. Rees, Basic engineering plasticity, Elsevier, 2006

Instructor bio

Prof. R Ganesh Narayanan

IIT Guwahati

Prof.R. Ganesh Narayanan is a Professor at the Department of Mechanical Engineering, Indian Institute of Technology (IIT) Guwahati, India. His research areas of interest include Metal Forming and Joining. He has contributed many research articles in reputed journals and international conferences. He has edited few books including ‘Sustainable Manufacturing Processes’ published by Elsevier, ‘Sustainable Material Forming and Joining’ published by CRC press, ‘Strengthening and Joining by Plastic Deformation’ published by Springer Singapore, ‘Advances in Material Forming and Joining’ published by Springer India, and ‘Metal Forming Technology and Process Modeling’ published by McGraw Hill Education, India. He has also edited special issues of journals including ‘Advances in Computational Methods in Manufacturing’ in the International Journal of Mechatronics and Manufacturing Systems, and ‘Numerical Simulations in Manufacturing’ in the Journal of Machining and Forming Technologies. He has organized three international conferences at IIT Guwahati namely International Conference on Computational Methods in Manufacturing (ICCMM) in 2011, the 5th International and 26th All India Manufacturing Technology, Design and Research (AIMTDR) Conference in 2014, 2nd ICCMM in 2019. He has also organized a GIAN course on ‘Green Material Forming and Joining’ at IIT Guwahati in 2016.

Course certificate

The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.

The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).

Date and Time of Exams: May 4, 2025 Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.

Registration url: Announcements will be made when the registration form is open for registrations.

The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.

Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

CRITERIA TO GET A CERTIFICATE

Average assignment score = 25% of average of best 6 assignments out of the total 8 assignments given in the course.
Exam score = 75% of the proctored certification exam score out of 100

Final score = Average assignment score + Exam score

Please note that assignments encompass all types (including quizzes, programming tasks, and essay submissions) available in the specific week.

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.

Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Guwahati .It will be e-verifiable at nptel.ac.in/noc.

Only the e-certificate will be made available. Hard copies will not be dispatched.

Once again, thanks for your interest in our online courses and certification. Happy learning.

- NPTEL team

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