ISE 446- Metal Deformation Processes

Study of the characteristics of metal flow under different loading conditions. Theories, capabilities, and limitations of a wide range of deformation processes applied to industrial metalworking.

ABET Course Description

Prerequisites: ISE 240 or ISE 340, CVE 220, and CHE 333.

Course Materials:

• Course notes will be supplied by the instructor. A reading list of texts in metalworking, metal deformation theory, and the mathematical theory of plasticity will be supplied for reference purposes.

Prerequisites by Topic:

• Introductory metallurgy and dislocation theory course material.
• First course in strength of materials with 2-dimensional stress/strain analysis.

Course Objectives:

Students completing this course will have achieved the following objectives:

Topics:

• Introduction – overview of metal deformation processes, classification as primary and secondary; hot and cold working, basic limitations of deformation processing.
• Basic deformation principles – review of test data (cold working), magnitude of elastic strains, work hardening, ductility; volumetric strain in metals; instability in simple tension; empirical stress/strain relations; test procedures for hot working; empirical stress/strain-rate relations; design of parts/processes for available ductility.
• Applications of basic principles – homogeneous and inhomogeneous deformation; plastic work; the redundant work factor; simple analyses of secondary forming processes; limitations of drawing and rolling processes; design and control of rolling mills.
• Introduction to plasticity theory – analysis of stress and strain: biaxial stress systems.
• 3-dimensional stress systems, Mohr’s circles representation, strain transformation equations, Mohr’s circle for strain increments; criteria for yielding and plastic flow; isotropic hardening model; stress/strain increment relationships; representative and strain measures; plane strain and bulge testing of sheet metal.
• Application of plasticity theory – bending under tension; radial drawing; biaxial instability and forming limits; effect of die friction on pressures and forces; slab analysis methods.
• Introduction to slip-line field and bounding theorem.

Laboratory Assignment:

• At least one laboratory exercise is used to illustrate the deformation principles.

Instructor: Peter Dewhurst

Email: dewhurst@egr.uri.edu

Office: 103 Gilbreth

Phone: (401) 874-5194