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TMM4182 - Fundamentals of Metal Forming and Sustainable Manufacturing Processes

About

Examination arrangement

Examination arrangement: Aggregate score
Grade: Letter grades

Evaluation Weighting Duration Grade deviation Examination aids
Individual assignment 40/100
School exam 60/100 3 hours G

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 processes widely used in modern manufacturing industries, mainly including bulk forming and tube/profile forming groups. For forming of sheet, tube, and profile, the semi-finishing processes as well as bending-type manufacturing processes are focused. Forming processes such as extrusion, rolling, forging, wire/bar drawing, bending and others are introduced. Besides, some high-energy-assisted methods, flexible processes, intelligent forming systems driven by Industry 4.0 will be introduced.

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.

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.

More on the course

Facts

Version: 1
Credits:  7.5 SP
Study level: Second degree level

Coursework

Term no.: 1
Teaching semester:  AUTUMN 2023

Language of instruction: English

Location: Trondheim

Subject area(s)
  • Technological subjects
Contact information
Course coordinator: Lecturer(s):

Department with academic responsibility
Department of Mechanical and Industrial Engineering

Timetable

List view
Calendar view

Examination

Examination arrangement: Aggregate score

Term Status code Evaluation Weighting Examination aids Date Time Examination system Room *
Autumn ORD School exam 60/100 G 2023-12-06 15:00 INSPERA
Room Building Number of candidates
SL520 Sluppenvegen 14 1
SL410 blå sone Sluppenvegen 14 28
Autumn ORD Individual assignment 40/100

Release
2023-11-17

Submission
2023-11-24


10:00


14:00

INSPERA
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.
Examination

For more information regarding registration for examination and examination procedures, see "Innsida - Exams"

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