Principles of Metal Forming Technology | EveryEng

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Principles of Metal Forming Technology

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1221 min

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Manufacturing & Industrial

Manufacturing Engineering

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Why enroll

Participants join this course to gain a clear understanding of how metals are shaped through plastic deformation and how forming processes are applied in modern manufacturing. The course builds strong fundamentals in material behavior, metal flow, and formability, enabling learners to analyze and understand the mechanics behind various metal forming operations.

The program is highly beneficial for students and professionals aiming to work in manufacturing, production, automotive, aerospace, and heavy engineering industries. It enhances the ability to select appropriate forming processes, materials, and process parameters while addressing common forming defects and quality issues. Exposure to both conventional and modern forming techniques strengthens practical and analytical skills relevant to industrial applications.

By joining this course, participants develop a solid foundation for advanced studies in manufacturing technology and gain industry-relevant knowledge that supports careers in process design, tooling, production planning, and manufacturing optimization.

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Is this course for you?

You should take this if

You work in Manufacturing & Industrial
You're a Manufacturing Engineering / Mechanical Engineering professional
You have 3+ years of hands-on experience in this field
You prefer self-paced learning you can revisit

You should skip if

You're new to this field with no prior experience
You need a different specialisation outside Manufacturing Engineering
You need live interaction with an instructor

Course details

Principles of Metal Forming Technology is a core manufacturing engineering course that focuses on the science and engineering principles involved in shaping metals through plastic deformation. The course provides a comprehensive understanding of how metals behave under applied stresses beyond their elastic limit and how this behavior is utilized in industrial forming processes to produce components with desired shapes, dimensions, and mechanical properties.

The course begins with an introduction to the fundamentals of plastic deformation, including stress–strain behavior, yield criteria, flow rules, strain hardening, and the effects of temperature and strain rate on metal flow. Concepts of metal flow, formability, and workability are explained to help students understand the limits and capabilities of different materials during forming operations.

Various metal forming processes are studied in detail, including rolling, forging, extrusion, drawing, and sheet metal forming operations such as bending, deep drawing, and stretch forming. The working principles, process parameters, tooling, and equipment used in each process are discussed along with advantages, limitations, and typical industrial applications. The course also introduces defects in metal forming, such as cracking, wrinkling, and residual stresses, and methods for their prevention and control.

In addition, the course covers analytical and empirical approaches to metal forming analysis, including force and power requirements, friction and lubrication, and basic process modeling. Modern developments such as computer-aided metal forming, finite element analysis, and advanced forming techniques are introduced to provide exposure to current industrial practices.

By the end of the course, learners gain a strong theoretical foundation and practical insight into metal forming technologies, enabling them to analyze forming processes, select appropriate methods and materials, and contribute effectively to manufacturing process design, optimization, and quality improvement in metalworking industries.

source : NPTEL[youtube]

Course suitable for

Key topics covered

introduction to principles of metal forming technology
concept of stress & strain
state of stress in three dimension
introduction to theory of plasticity and flow curve
instability in tension
classification of metal working processes

Course content

The course is readily available, allowing learners to start and complete it at their own pace.

39 lectures20 hr 21 min

Introduction to Metal Forming Technology
31 min
Classification of Metal Working Processes
30 min
Behavior of Materials
33 min
Failure of Materials
31 min
Concept of stress and strain
29 min
Description of stress
30 min
State of stress in three dimension
30 min
Hydrostatic and deviator components of stress and strain
30 min
Elastic stress strain relationships
30 min
Introduction to theory of plasticity and flow curve
31 min
True stress and true strain
30 min
Yield criteria for ductile materials
30 min
Yield locus, Octahedral shear stress and strain
31 min
Plastic stress strain relationships
32 min
Measures of yielding and ductility in tensile testing
32 min
Instability in tension
34 min
Strain rate effects on flow properties
31 min
Temperature effects on flow properties
30 min
Influence of various parameters on flow properties
32 min
Classification of metal working processes-2
32 min
Mechanics of metalworking and analysis methods
33 min
Determination of flow stresses in metal working
29 min
Hot working and cold working
31 min
Metallurgical considerations in metal forming
35 min
Introduction and classification of forging processes
31 min
Equipments used in forging
30 min
Forging in plane strain
31 min
Introduction and classification of rolling processes
32 min
Analysis of rolling load calculations
33 min
Defects in rolled and forged products
28 min
Introduction and classification of extrusion processes
32 min
Analysis of extrusion processes
30 min
Extrusion of tubes and pipes, extrusion defect
33 min
Introduction to rod and wire drawing
32 min
Analysis of wire drawing and tube drawing processes
32 min
Sheet metal operations-I
33 min
Sheet metal operations-II
32 min
Powder metallurgy forming-I
34 min
Powder metallurgy forming-II
31 min

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Questions and Answers

Q: You're troubleshooting edge cracking during cold rolling of low-carbon steel strip, and you catch yourself typing "edge cracks after cold rolling low carbon steel strip cause" into Google. The cracks appear only near the edges, elongate with reduction, and disappear when the mill backs off reduction per pass. What's the root cause that best fits all observed symptoms?

A: Principle: Plastic deformation localizes where stress state and material strength interact unfavorably. Here the edge sees higher tensile stress from crown mismatch, and work hardening accelerates cracking as reduction increases. Backing off reduction lowers edge strain and arrests it. B catches engineers who know inclusions cause cracks, but those wouldn't turn off just by easing reduction per pass.

Q: During a forging operation, the light curtain on a mechanical press fails to trip, and you're asked what the real exposure is. You're searching "mechanical press light curtain failure consequence" while the line is down. What physical hazard does the light curtain NOT protect against?

A: Principle: Presence-sensing safeguards stop motion but don't remove stored mechanical energy. A flywheel clutch failure can still transmit energy regardless of light curtain state, leading to uncontrolled motion. The other options are exactly what the curtain is meant to interrupt. C trips up people who assume control faults bypass presence sensing, but the safeguard still inhibits motion on detection.

Q: In a deep drawing line, blank holder force was increased to reduce wrinkling, and now tearing shows up near the cup wall. You're googling "increase blank holder force causes tearing deep drawing" while production waits. What's the correct response?

A: Principle: Material flow must be restrained without over-constraining it. Excessive holder force starves the wall of material, raising tensile strain and causing tears. Using draw beads restores control while lowering global restraint. D tempts engineers who know lubrication helps, but it doesn't fix the over-restraining stress state.

Q: A vendor-supplied forming simulation report is based on Rev 2 material data, but the mill cert shows Rev 4 chemistry. You're searching "forming simulation wrong material revision failure mode". Parts crack in production even though the FEA predicted safe strain. What's the most likely reason?

A: Principle: Formability predictions hinge on accurate material flow stress and hardening behavior. A chemistry change can drop n-value, making localized necking happen earlier than the model shows. That's consistent with cracks despite 'green' results. B catches people focused on modeling practice, but coarse mesh wouldn't suddenly break correlation only after a material rev change.