ABET SYLLABUS FORMAT

MFGG-404 Sheet Metal Forming

Jun 2002

2002 Catalog data: This course demonstrates the need for thinking one’s way through manufacturing situations rather than calculating. Special material properties important to forming are developed followed by a discussion of strain generation and measurement techniques including Circle Grid Analysis and Forming Limit Diagrams. The fabricating processes of shearing, bending, drawing and stretching are investigated thoroughly. Special forming processes and simulation testing are also discussed. The interaction of tooling, presses and lubrication completes the study of sheet metal forming. Laboratory experiences on production-grade presses complement the lecture.

Textbook(s): None

References: Notes will be provided by the professor.

Coordinator: Professor William J. Riffe

Course Learning Objectives:

1. Explain the material properties that are important in forming and calculate the special material properties from tensile test data. (Program Outcome A, B, C, E, F, G, H, I, J, K, L, M, N, O, P)

2. Apply and read strain circles and analyze stampings using a Forming Limit Diagram. (Program Outcome A, B, C, D, E, G, I, K, L, M, P)

3. Compare and contrast the various methods of shearing and forming sheets. (Program Outcome A, B, C, E, I, K, L, M, N, P)

4. Describe the influence of tooling parameters on the formability of sheets in bending, drawing, and stretching. (Program Outcome A, B, C, E, G, I, J, K, L, M, N, P)

5. Effectively communicate the technology of stamping in a written term paper. (Program Outcome D, E, F, G, H, I, J, K, P)

Prerequisites by Topic:

1. Basic material properties and testing

2. Stress and strain concepts

Topics covered:

1. Discussion of material properties and the calculation from tensile tests

2. Strain measurement, Circle Grid Analysis and Forming Limit Diagrams

3. Shearing processes

4. Forming processes – bending, drawing, stretching

5. Simulated forming tests

6. Special forming processes, tool materials, prototyping and presses

7. Lubricants

8. Hydroforming

Schedule:

Three sessions of 60 minutes each for lecture

One session of 120 minutes for laboratory

Computer Usage:

Write-up of laboratory experiments including graphing

Spreadsheet calculation and graphing

Word processing of final paper

Laboratory Projects:

1. Material property calculation

2. Bending including strain measurement

3. Effect of die entry radius

4. Effect of punch nose radius

5. Effect of clearance

6. Hole expansion

7. Stretching

8. Lubrication

9. Square and rectangular pans

Relationship to professional practice: Two units of engineering science and two units of engineering design.

Prepared by: _____William J. Riffe_______ Date: ___July 2002____