This seminar covers metal forming and related manufacturing processes, emphasizing practical applications. From forged or P/M connecting rods to tailor-welded blank forming, metal parts are integral to the automotive industry. As a high value adding category of manufacturing, metal forming is increasingly important to the core competency of automobile manufacturers and suppliers. A thorough survey of metal forming processes and metal forming mechanics will be performed, including bulk deformation, sheet-metal, and powder metallurgy operations. Design considerations are fully integrated into the course and are presented with every process. A large number of real-world case studies are presented to the attendees to emphasize course content.

Attendees will receive a copy of the book "Manufacturing Engineering Technology," co-written by instructor Steven R. Schmid.

• Identify the unique characteristics of metals that lead to plastic deformation as a processing strategy
• Explain the processes involved in metal forming mechanics, materials, and tribology
• Analyze the interrelationships between various factors that influence the quality of manufactured products
• Describe sheet metal characteristics and forming
• Describe the wide variety of processes used to shape and deform metals, including forging, rolling and extrusion; sheet metal forming, shearing and stamping; powder metallurgy processes and assorted other processes

• Overview of Solid Mechanics and Materials Science Topics of Importance to Metal Forming
• Tribology of Metal Forming: Friction, Lubrication and Wear
• Bulk Deformation Processes
  • Forging: open die and closed-die (impression) forging; machinery description and capabilities; forging process layout and die design; heading, coining, piercing and upsetting operations; swaging
  • Rolling: flat rolling process, including Orowan model; control of product quality including surface finish and gage control; rolling equipment and capabilities; shape rolling; ring rolling
  • Extrusion and drawing: direct, indirect and hydrostatic extrusion; cold and hot extrusion; die design; defects in extrusion; drawing equipment and mechanics; limiting drawing ratio

• Sheet Metal Forming Processes
  • Sheet metal shearing: mechanics of shearing, burr formation, blanking operations, fine blanking
  • Sheet metal bending: types of bending operations and equipment; springback calculation and control; tube bending
  • Sheet forming operations: deep drawing and ironing; stretch forming; bulging, rubber forming and hydroforming; roll forming of sheet; spinning; incremental forming; explosive, peen and other specialty forming processes; stamping operations and die design
  • Sheet metal formability: limiting drawing ratio for deep drawing; sheet metal formability; forming-limit diagrams
• Powder Metallurgy Processes
  • Compaction through pressing, cold and hot isostatic pressing and metal injection molding; sintering mechanics and processes; coining and finishing

"This is a very good short program on metal forming for product design engineers."
Yanjun Huang
Principal Engineer - Materials
Key Safety Systems, Inc.

"Very good seminar for engineers to understand the basics of metal forming processes."
Andrew Chen
Engineering Manager - CAE
ZF Lemforder Corp.