Course content

The course covers manufacture of metallic products by casting and metal forming. Design of cast and metal formed components. Casting methods, mould and ingot mould. Casting of iron, steel and light metals. Melt flow, solidification, heat transfer, contraction, thermal stresses, foundry management, quality, environmental considerations and costs. General metal forming theory: Technological tests, flow stress, friction, thermal conditions. Analysis of metal forming processes as forging, rolling, drawing, extrusion and sheetmetal forming by classical theory and modern FEM-analysis.

Learning outcome

The course gives a fundamental introduction into the technology of casting and metal forming. To be dealt with are construction of cast components, understanding of different casting methods, production and use of important casting alloys, foundry management, control of quality, environment and costs. In metal forming the students will learn how to analyse and to optimise common metal forming operations.

Learning methods and activities

Lectures, calculation- and laboratory exercises. There will be two semester projects where casting and metal forming are analysed in laboratory experiments supported by FEM-analysis using the FEM-programs DEFORM and MAGMASOFT. A mark is given for the semester projects/exercises, and this mark counts 40% when final mark is given. Lectures and exercises will be in English if some students do not speak Norwegian. If there is a re-sit examination, the examination form may be changed from written to oral.

Compulsory assignments

• Exercises

Recommended previous knowledge

Background knowledge comparable with TMM4100 Materials Technology 1.

Course materials

Distributed compendium. (Support literature: J. Campbell: Castings, Butterworth/Heinemann, 1993 eller 2003.)
Selected chapters from the book: Henry Valberg: Applied metal forming including FEM-analysis.