TMM4182 - Fundamentals of Metal Forming and Sustainable Manufacturing Processes


Examination arrangement

Examination arrangement: Portfolio assessment
Grade: Letters

Evaluation Weighting Duration Grade deviation Examination aids
Works 50/100
Home examination 50/100 4 hours

Course content

The course deals with the fundamental issues related to design and manufacturing of metallic products by metal forming. The main content will specially focus on four parts:

Part I: Introduction of metallic materials and manufacturing

This part includes overview of metallic materials (classification, production, and general properties, etc.), and overview of metal products and manufacturing methods (casting, extrusion, forming, machining, and additive manufacturing, etc.).

Part II: Fundamental theory of metal forming

This part includes 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. In addition, knowledge basis about finite element (FE)-analysis for metal forming is presented in this part.

Part III: 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 IV: Sustainability in metal forming

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 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 analyse 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.


  • 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 mandatary.

  • 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 or DEFORM-3D as an effective tool to design and analyze metal forming processes.
  • Laboratory exercises: The experimental training related to aluminium 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 aluminium 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

Portfolio assessment is the basis for the grade in the course. The portfolio includes a home examination (50%) and compulsory project works (50%). The results for the parts are given in %-scores, while the entire portfolio is assigned a letter grade.

If there is a re-sit examination, the examination form may be changed from home examination to oral.

For a re-take of an examination, all assessments during the course must be re-taken.

Specific conditions

Compulsory activities from previous semester may be approved by the department.

Course materials

H. Valberg, Applied Metal Forming Including FEM-analysis, Cambridge University Press, 2010.

M.P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems (7th Ed.), John Wiley & Sons, 2020. (Parts I, II and V)

A.E. Tekkaya and S. Chatti, Bending (Tubes, Profiles), in: S. Chatti, L. Laperrière, G. Reinhart, T. Tolio, (Eds.) CIRP Encyclopedia of Production Engineering, 2014.

J. Duflou, Bending (Sheets), in: S. Chatti, L. Laperrière, G. Reinhart, T. Tolio, (Eds.) CIRP Encyclopedia of Production Engineering, 2014.

F. Jovane, E. Westkämper, D. Williams, The Manufuture Road: Towards Competitive and Sustainable High-Adding-Value Manufacturing, Springer, 2008.

Ingarao, G., Di Lorenzo, R., Micari, F., 2011. Sustainability issues in sheet metal forming processes: An overview. J. Clean. Prod. 19, 337-347.

More on the course

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


Term no.: 1
Teaching semester:  AUTUMN 2021

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


Examination arrangement: Portfolio assessment

Term Status code Evaluation Weighting Examination aids Date Time Examination system Room *
Autumn ORD Works 50/100
Room Building Number of candidates
Autumn ORD Home examination (1) 50/100





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.
  • 1) Merk at eksamensformen er endret til hjemmeeksamen som et smittevernstiltak i den pågående koronasituasjonen.

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

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