Ambo University Institute of Technology

Metal Processing Technology (MEng 5324)

Department of Mechanical Engineering
Course No MEng 5324
Course Title Metal Processing Technology
Program BSc in Mechanical Engineering
Module Manufacturing Engineering Electives
Instructor Murtesa D.
Credits 3
ECTS credit 5
Contact Lecture Tutorial Practice or Lab Home study
Hours/week 32 48 0 55
The course enable students to:
 Identify raw materials, equipment and process and finished products of different metal
Course objective & processing industries;
Competences to be
 Specify raw materials and finished products of metal processing;
Acquired
 Understand the design aspect of roll passes, sheet metal rolling processes;
 Understand finishing methods and their processes.
1. Fundamentals of Metal forming
1.1. Overview of Metal Forming
1.2. Material Behavior in Metal Forming
1.3. Temperature in Metal Forming
1.4. Strain Rate Sensitivity
1.5. Friction and Lubrication in Metal Forming…………………….. (5hrs).
2. Rolling processes
2.1. Flat Rolling and Its Analysis
2.2. Shape Rolling
2.3. Rolling Mills
2.4. Other Deformation Processes Related to Rolling…………………………… (5hrs).
3. Forging processes
3.1. Open-Die Forging
3.2. Impression-Die Forging
3.3. Flashless Forging
3.4. Forging Hammers, Presses, and Dies
3.5. Other Deformation Processes Related to Forging…………………………. (5hrs).
4. Extrusion processes
Course Description
4.1. Types of Extrusion
/course content
4.2. Analysis of Extrusion
4.3. Extrusion Dies and Presses
4.4. Other Extrusion Processes
4.5 Defects in Extruded Products……………………………………………… (5hrs).
5. Rod, Wire, and Tube Drawing
5.1.Wire and Bar Drawing
5.2. Analysis of Drawing
5.3. Drawing Practice
5.4. Tube Drawing
5.5. Drawing Defects and Residual Stresses………………………………… (5hrs).
6. Sheet-metal Forming
6.1. Cutting Operations
6.2. Bending Operations
6.3. Drawing
6.4. Other Sheet-Metal-Forming Operations
6.5. Dies and Presses for Sheet-Metal Processes
6.6. Sheet-Metal Operations Not Performed on Presses..…………………….. (6hrs).
7. Powder Metallurgy
 Ambo University Institute of Technology
7.1. Characterization of Engineering Powders
7.2. Production of Metallic Powders
7.3. Conventional Pressing and Sintering
7.4. Alternative Pressing and Sintering Techniques
7.5. Materials and Products for Powder Metallurgy
7.6. Design Considerations in Powder Metallurgy …………………………..….(6hrs)
Pre-requisites MEng 2092 (Engineering Materials II)
Semester 10th
Course Status Professional Elective
Course Policy 75% lecture attendance and 100% of others
 Lectures supported by tutorials
Teaching and
 Individual Design Project
Learning methods
 Industrial/Agricultural Site Visits
Evaluation systems  Test 1 20%
 Test 2 20%
 Project 20%
 Final Examination 40%
References 1. Mikell P. Groover, Fundamentals of Modern Manufacturing Materials,
Processes, and Systems, 4th edition, 2010.
2. S. Kalpakjian, Steven R. Schmid, Hamldon Musa, Manufacturing Engineering
and Technology, 6th edition, 2009.
3. GEORGE E. DIETER, JR. Mechanical Metallurgy.
4. Robert W. Cahn, Materials Science and Technology, Materials Science and
Technology A Comprehensive Treatment - Volume 15: Processing of Metals and
Alloys Cahn,R.W.(ed.)/Haasen,P.(ed.)/Kramer,E.J.(ed.) and Technology: A
Comprehensive Treatment), Dec 16, 1996.
5. Robert W. Chan, Materials Science and Technology: A Comprehensive
Treatment: Processing of Metals and Alloys (Materials Science and
Technology), Sep 1991.

Course approval section

Instructor Name HOD Name Quality Assurance

Murtesa D. ___________________ ____________________
Signature: ____________ _______________ ________________
Date: ____________ _____________ ________________
 Ambo University Institute of Technology

MEng 4305, Metal Forming Processes and Analysis

Department of Mechanical and Vehicle Engineering
School of Engineering & Information Technology, Adama Science and Technology University
Course Number
MEng 4305
Course Title
Metal Forming Processes and Analysis
Degree Program
BSc in Mechanical Engineering
Competency
Competency Chair
Module
22
Module Coordinator
Lecture
ECTS Credits
4
Contact Hours
Lecture
Tutorial
Practice or Laboratory
Home study
2
0
3
3
Course Objectives:
The course enables students to understand:

-forming process of selected processes;

Course Description:
stress tensor and yield criteria, fundamentals of metal forming, forging and rolling, extrusion and drawing , sheet
metal forming and other processes
Course Outline:
1. FUNDAMENTALS OF METAL FORMING
Classification of forming processes, Yield Criteria: Von Mises, Tresca, Mechanics of metal working, Flow stress
determination, Effect of temperature, stain rate and metallurgical structure on metal working, Friction and
lubrication. Deformation zone geometry, Workability, Residual stresses.
2. FORGING AND ROLLING
Forging-types of presses and hammers. Classification. Open die forging and Closed die forging, die design, forging
in plane strain, calculation of forging loads, forging defects- causes and remedies, residual stresses in forging.
Rolling: Classification of rolling processes, types of rolling mills, hot and cold rolling, rolling of bars and shapes,
forces and geometrical relationship in rolling, analysis of rolling load, torque and power, rolling mill control, rolling
defects - causes and remedies.
3. EXTRUSION AND DRAWING
Direct and indirect extrusion, variables affecting extrusion, deformation pattern, equipments, Port-hole extrusion die,
hydrostatic extrusion, defects and remedies, simple analysis of extrusion, tube extrusion and production of seamless
pipe and tube. Drawing of rods, wires and tubes.
4 SHEET METAL FORMING AND OTHER PROCESSES
 Ambo University Institute of Technology
Undergraduate Curriculum – Department of Mechanical and Vehicle Engineering July 2011
__________________________________________________________________________________
Adama Science and Technology University, School of Engineering and Information Technologies
107
Forming methods - Shearing, blanking, bending, stretch forming, deep drawing. Types of dies used in press
working, defects in formed part, sheet metal formability, formability limit diagram.
Pre-requisites:
MEng 2302 Workshop Technology II
Semester:
7th
Status of Course:
Compulsory
Teaching and Learning methods

Project Work:
Producing different parts using metal forming processes
Assessment/ evaluation & Grading Systems
Assessment/ evaluation & Grading system

-semester Examination 30%, and

Attendance Requirement:

Literature:
Referance
1. Nagpal. G.R., “Metal Forming Processes”, Khanna Pub., New Delhi, 2000
2. Dieter.G.E., “Mechanical Metallurgy”, McGraw-Hill Co. SI Edition. 1995.
3. B.H.Amstead, and others,”Manufacturing process”, John Wiley & Sons Ltd., New York, 1977.,
4. Roger Pierce, “Sheet metal forming”, Adam Hilger, New York, 1991.
5. B. Kumar, Sujay Kumar, “Manufacturing process and technology” ,Khanna publishers, Delhi, 2002.
. Kurt Lange “Handbook of Metal Forming”. Society of Manufacturing Engineers. Michigan. USA. 1988
6. Avitzur, “Metal Forming - Processes and Analysis”, Tata McGraw-Hill Co. New Delhi, 1977.
7. ASM Metals Handbook. Vol.14, “Forming and Forging”, Metals Park, Ohio, USA, 1990.
8. Taylor Altan, Soo I.K. Oh, Harold.L.Gegel. “Metal Forming: Fundamentals and Applications”, ASM. Metals
Park. Ohio, USA, 1983.