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Advanced Metal Forming

Unit Code: HES6128




Duration

Contact Hours

Campus

Prerequisite

Corequisite


12 weeks

36 hours

Hawthorn


Nil


Nil

Credit Points: 12.5 Credit Points

Related Course/s:

 
 

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Aims & Objectives:

The aim of this unit is to provide student with the fundamental understanding of mechanics & various materials used in metal forming processes and skills related to a computational modeling of sheet forming process which is widely used in modern metal forming industry.

At the successful completion of this unit, student should be able to:
  • Understand the basic mechanics on anisotropic plasticity for bulk and sheet forming processes
  • Describe forming limit & fracture for steel and aluminium sheets
  • Describe how to prepare the material input data for finite element modelling through material characterization
  • Develop and Apply the algorithm for computational mechanics for metal forming
  • Apply computational modelling skill for forming simulation
  • Evaluate the basic design methodologies for metal forming Content

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Teaching Methods:

Lectures, Tutorials

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Assessment:

Written Exam (worth 60%),
Assignment (worth 40%)

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Generic Skills Outcomes:

Student will be provided with feedback on the progress in attaining the following generic skills:
  • analysis and modeling skills,
  • problem solving skills,
  • communications skills,
  • teamwork skills,
  • ability to work independently

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Content:

  • Nonlinear kinematics and anisotropic plasticity to describe the large deformation of metals
  • Experimental materials characterization and constitutive parameters for modeling
  • Instabilities including necking, buckling, springback, surface crack, and fracture which occurs during metal forming
  • Modern forming limit (strain & stress-based) and fracture models to predict the instabilities
  • Finite element modeling of sheet metal forming process
  • Product design and optimization methods to meet the design criteria within constraints

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Textbooks:

Nil

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References:


1. Hosford, W.F. and Caddell, R., M., 1983. Metal forming : Mechanics and Metallurgy, Prentice-
    Hall, Inc., Englewood Cliffs, N.J., ISBN: 0135561353.
2. K. J. Bathe, 1996. Finite Element Procedures, Prentice Hall.
3. R.H. Wagoner, J.L. Chenot, 1996, Fundamentals of metal forming, Wiley, ISBN: 0471570044.
4. J. Bonet, R.D. Wood, 1997. Nonlinear continuum mechanics for finite element analysis,
    Cambridge University Press, ISBN : 052157272X 9780521572729
5. J.W. Yoon, F. Barlat, 2006. Article in ASM Handbook, Modeling and Simulation of the Forming
    of Aluminum Sheet Alloys, Vol.14B, Metal Working: Sheet Forming, ASM International,
    Materials Park (OH), 792-826.
6. J.W. Yoon, 2007. Advances in Metal Forming: Experiments, Constitutive Models &
    Simulations, Vol.23, No.3, Int. J. Plasticity.

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