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MSE course syllabi

Materials Science and Engineering 666

Deformation Processing

 

Catalog Data:

Continuum behavior of metals; analysis of common forming operations; slab calculations, ideal work methods, upper bound analysis, other numerical methods. Wi Qtr. Elective

Prerequisites:

ME 420 or ME 440 (Strength of Materials).

Time Distribution:

3-48 min lecture classes per week.

Objectives:

  1. Understand the principles and limitations of metal forming operations and their continuum analysis,
  2. Learn to use cutting-edge finite element analysis techniques applied to metal forming, and
  3. Appreciate the competing advantages of closed-form analytical methods and numerical methods. Meet ABET Criteria 3 Outcomes: a, b, c, e, i, k.

Textbooks:

R. H. Wagoner and J.-L. Chenot: Fundamentals of Metal Forming, John Wiley & Sons, 1997, 387 pages.

References:

"Metal Forming", Hosford and Caddell, Prentice-Hall, 1983

George E. Dieter: "Mechanical Metallurgy - 2nd Edition," McGraw Hill, 1976.

M. A. Meyers and K. K. Chawla: "Mechanical Metallurgy Principles and Applications," Prentice-Hall, 1984.

J. N. Harris: "Mechanical Working of Metals," Pergamon Press, 1983.

S. C. Charpra and R. P. Canale, “Numerical Methods for Engineers - 2nd edition”, McGraw-Hill, 1985.

Lecture Topics :

  1. Classification of Forming Processes (history and definitions)
  2. Plasticity (yield function, hardening, normality, strain rate effects)
  3. Tensile Test Analysis (plastic instability, finite element analysis*)
  4. Forming Concepts (work of deformation: ideal, redundant; friction & lubrication, ideal energy method)
  5. Drawing and Extrusion (slab analysis, finite element analysis*)
  6. Forging (slab analysis, finite element analysis*)

Lab Assignments:

  1. Tensile test analysis (2-D finite element analysis, Abaqus CAE)
  2. Drawing/Extrusion (2-D finite element analysis, Abaqus CAE)
  3. Plane-strain Forging (2-D finite element analysis, Abaqus CAE)

Computer Usage:

Extensive, 1 preliminary Abaqus CAE problem, 3 CAE laboratory problems, 1 data preparation problem using Excel – then transferred to Abaqus CAE.

Grading Plan:

3 major CAE laboratory reports – 3 x 15% = 45%, 10% other homework, 45% midterm examination

Professional Component Content:

Engineering Science: 1.0 credit, or 33%

Engineering Design: 2.0 credit, or 67%

Design Component Content:

In lectures, students learn the principles of metal forming analysis, applied plasticity, the effect of material properties on forming operations, and the use of closed-form mathematical representations of forming operations to predict the success and efficiency of a proposed forming operation. In computer laboratory sessions, students learn to use a cutting-edge nonlinear finite element analysis program, and to apply it to the design of effective, efficient, and reliable metal forming operations.

Relation to Program Objectives:

  1. Course teaches fundamentals of metal forming from a continuum property point of view, including plasticity theory.
  2. Analytical and computational skills are developed in weekly problem sets and more extensive numerical problem assignments.
  3. Course connects continuum material properties with performance during component processing and manufacture.
  4. Prepare students to apply engineering and materials fundamentals to manufacturing processes.

Academic Integrity, Academic Misconduct

Academic misconduct may be found in any action that tends to distort the accurate assessment of any student’s individual accomplishments that are evaluated for the purpose of grading or conferring academic credit. Note that a student may be guilty of academic misconduct, for example, by cheating, collaborating, plagiarizing, or by allowing another student to cheat, collaborate, or plagiarize. Note also that the distortion applies, for example, to exams, homework assignments, and laboratory work. To the extent that any class activity (for example: attendance or participation) is used for evaluation for the purpose of grading or conferring academic credit, falsifying or distorting such activity, or permitting another student to falsify or distort such activity, represents academic misconduct.

Additional guidance about what represents academic integrity and misconduct, and related university-wide policies and procedures are available at the following locations:

http://oaa.osu.edu/coam/faq.html

http://oaa.osu.edu/coam/ten-suggestions.html

Course-specific exceptions or amplifications to the departmental and university statements outlined above will be provided by the faculty instructor in writing, preferably as part of the course syllabus.

Note: Students should not request nor accept guidance on these matters from a teaching assistant, fellow student, or anyone other than the faculty instructor of record for this course.

Disabilities Statement

Any student who feels s/he may need an accommodation based on the impact of a disability should contact the Office for Disability Services at 614-292-3307 in room 150 Pomerene Hall to coordinate reasonable accommodations for students with documented disabilities. (URL: http://www.ods.ohio-state.edu/)

Advice on such matters is also available from the MSE department’s undergraduate adviser (1xx-6xx courses) and graduate coordinator (7xx-9xx courses) whose offices may be found in room 477 Watts Hall.

Megan Daniels, Undergraduate Advisor, (614) 292-3145, e-mail Megan concerning the MSE undergrad studies

Mark Cooper, Graduate Studies Coordinator, (614) 292-7280, e-mail Mark concerning the MSE graduate studies