Course - Fundamentals of Metal Forming and Sustainable Manufacturing Processes - TMM4182
TMM4182 - Fundamentals of Metal Forming and Sustainable Manufacturing Processes
About
Examination arrangement
Course content
The course deals with the fundamental issues related to design, development and manufacturing of metallic products by metal forming. The main content will especially focus on four parts:
Part I: Fundamental Theory of Metal Forming
In this part, an overview of metallic materials, metal products and manufacturing methods (casting, extrusion, forming, machining, and additive manufacturing, etc.) will be introduced first. Then, the physical basis of plasticity, mechanical behavior of metallic materials, strain and stress, flow stress, anisotropy, formability, temperature condition, strain rate sensitivity, friction and lubrication, and other critical aspects, will be taught. In addition, knowledge base about finite element (FE) analysis for metal forming is presented.
Part II: Fundamental Metal Forming Processes
This part introduces fundamental metal forming processes widely used in modern manufacturing industries, such as extrusion, rolling, forging, wire/bar drawing, advanced bending, and others. Forming-based joining, additive manufacturing processes based on material flow, and hybrid manufacturing processes are also introduced. In addition, advanced manufacturing processes toward carbon-neutral and Industry 4.0-based intelligent forming systems will be introduced and discussed.
Part III: Course Project: Design and Analysis of Advanced Industrial Bending Processes
In this part, a case study on design and analysis of an advanced forming process will be performed. Student groups will be guided to use analytical and FE numerical methods to design and analyze an industrial bending process for tubes and profiles. In addition, an experimental lecture will be given, in which the students can work in MANULAB to do the forming experiments to validate the design and analysis.
Part IV: Sustainability in Metal Forming and Manufacturing
In this part, the issues of environmental sustainability related to metal forming are introduced. The main aspects are focused on material choice and utilization, lightweight design of structure, forming process and system, energy-saving during production, recycling of end-of-life metals like aluminum alloys.
Learning outcome
Knowledge:
- Knowledge about manufacturing of metallic products, fundamentals of scientific theory and key technologies, and the future trend of metal forming based product development and Industry 4.0 principles.
- Understand how to design and analyze metal forming processes, and how to develop and manufacture products in an industrial context - using both fundamental theory, finite element (FE) -analysis, and physical experiments.
- Understand sustainability aspects related to metal forming, thus pursuing decisions and activities which would lead to a more efficient use of materials and energy.
Skills:
- Capability to use fundamental theoretical and practical skills related to metal forming to design and develop products for sustainable manufacturing.
- Capability to use FE analysis and modern data-assisted methods for optimizing metal forming process towards improved product quality and reduced cost.
- Practical skills from laboratory experiments of manufacture high value-added products.
General competence:
The students will have general competence regarding product design and development, and sustainable manufacturing technologies. More specifically, the students are able to design and develop forming processes for advanced and innovative metal products. The competence acquired can be described by the key words: advanced manufacturing, fundamental theories and methods, design and development of sustainable products.
Learning methods and activities
The course will be a combination of Lectures, FE-simulation training, and Laboratory exercises. All of them are mandatory.
- Lectures: Both presentations and blackboard are used in parallel for teaching. The students get the teaching materials through Blackboard.
- FE simulation training: The students are taught the basic knowledge and operation of FE simulation, as well as how to use the FE program, for example, ABAQUS, as an effective tool to design and analyze metal forming processes.
- Laboratory exercises: The experimental training related to aluminum extrusion and forming (bending) process will be arranged in the ManuLab at MTP.
There will be semester projects focusing on analyzing forming processes, for instance the advanced bending of aluminum profile products. In the project, the forming theory, FE-simulation and experimental verification will be totally used to complete the whole analysis.
Compulsory assignments
- Exercises
Further on evaluation
Writing school exam: 60%, assignment and project report: 40%.
If there is a re-sit examination, the examination form may be changed from school exam to oral.
For a re-take of an examination, all assessments during the course must be re-taken.
Recommended previous knowledge
Knowledge related to TMM4100 Materials Technology.
Course materials
H. Valberg, Applied Metal Forming Including FEM Analysis, Cambridge University Press, 2010.
MP Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems (7th Ed.), John Wiley & Sons, 2020. (Parts I, II and V)
AE Tekkaya and S. Chatti, Bending (Tubes, Profiles), in: S. Chatti, L. Laperrière, G. Reinhart, T. Tolio, (Eds.) CIRP Encyclopedia of Production Engineering, 2014.
KR Haapala et al. A review of engineering research in sustainable manufacturing. J Manuf Sci Eng Trans ASME 135:1-16, 2013.
Version: 1
Credits:
7.5 SP
Study level: Second degree level
Term no.: 1
Teaching semester: AUTUMN 2024
Language of instruction: English
Location: Trondheim
- Technological subjects
Department with academic responsibility
Department of Mechanical and Industrial Engineering
Examination
Examination arrangement: Aggregate score
- Term Status code Evaluation Weighting Examination aids Date Time Examination system Room *
- Autumn ORD School exam 60/100 G 2024-11-25 15:00 INSPERA
-
Room Building Number of candidates SL110 hvit sone Sluppenvegen 14 28 -
Autumn
ORD
Individual assignment
40/100
A
Release
2024-11-13Submission
2024-11-20
10:00
INSPERA
16:00 -
Room Building Number of candidates - Summer UTS School exam 60/100 G INSPERA
-
Room Building Number of candidates
- * The location (room) for a written examination is published 3 days before examination date. If more than one room is listed, you will find your room at Studentweb.
For more information regarding registration for examination and examination procedures, see "Innsida - Exams"