Course: Experimental Methods in Metal Forming

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Course title Experimental Methods in Metal Forming
Course code KSP/EMMF
Organizational form of instruction Lecture + Lesson
Level of course Master
Year of study not specified
Semester Winter
Number of ECTS credits 5
Language of instruction English
Status of course Compulsory-optional
Form of instruction Face-to-face
Work placements Course does not contain work placement
Recommended optional programme components None
Course availability The course is available to visiting students
Lecturer(s)
  • Solfronk Pavel, doc. Ing. Ph.D.
  • Sobotka Jiří, Ing. Ph.D.
Course content
1. Classification of forming tests (standardized, technological, special). Criterions for selection suitable types of tests with respect to technology and technological conditions at forming. Utilization of experimental methods for analysis forming processes. 2. Basic methods and possibilities for scanning technical quantities participating in the forming process. Specific problems and limiting factors for utilization some types of sensors in the branch of metal forming. Possibilities of digital record, processing and evaluation of scanned process quantities. Selection of data filters suitable types for the individual measurements. 3. Fundamentals of photogrammetry and its utilization for deformation analysis of forming material. Mathematical background of photogrammetry. Industrial processing of image and machine vision. Contact-less optical systems for stationary (s. ARGUS) and continuous deformation analysis (s. ARAMIS). Possibilities of kinematic quantities contact-less monitoring (system PONTOS) and 3D surfaces digitalization (s. ATOS). 4. Introduction into theory of planning experiment. Basic operations with software for statistical processing of experimentally measured values. Computation of basic statistical indicators, importance of tolerance and confidence interval for one and two-dimensional case of measured data. Methods of regression analysis. Correlation coefficient and correlation index. Fundamentals of statistical hypothesis testing. 5. Detailed analysis of the static tensile test, possible factors influencing result of this test. Determination of normal and planar anisotropic coefficient. Computation of hardening curves and methods of their mathematical approximation in the area of homogenous and non-homogenous deformation. Selection of proper approximation functions with respect to type of testing material. Determination of material sensitivity on the strain rate (strain rate models). Methods used for determination Young´s modulus. 6. Utilization of thermal-mechanical simulator Gleeble to determine influence of temperature and strain rate on the form-strength and deformation ability for chosen types of materials designed for forming. 7. Principle, methodology of performing and evaluation of standardized material testing under bending, compressive, torsion and impact bending loading. 8. Principle, methodology of performing and evaluation of standardized hardness testing of materials acc. to HR, HV, HB. Micro-hardness tests. 9. Principle, methodology of performing and evaluation of technological forming tests. Erichsen drawing test, cup drawing test, bore expansion test with different magnitude of shear clearance. 10. Principle, methodology of performing and evaluation of material testing under multi-axial loading. Bi-axial tests by means of mechanical and hydrostatical loading. Methodology how to evaluate tests with respect to its utility for definition yield criterions. Yoshida test used for determination Bauschinger effect and its application for definition advanced yield criterions. 11. Utilization of deformation meshes (patterns) for the contact-less strain analysis. Requirements for deformation meshes and progressive methods for deformation meshes applications. Limiting factors influencing the application possibilities and accuracy of deformation meshes. Specific requirements for deformation meshes used for the full-area deformation analysis. 12. Methods for determination forming limit diagrams. Specificity of performing and evaluation of this test for deep-drawing and ultra high-strength materials, methods to eliminate friction. Importance of FLDs for the numerical simulation of forming processes. 13. Cyclic testes to determine fatigue properties of materials. 14. Basic principles of the tribological tests used in the metal forming. Selection of type and parameters for given tribological test.

Learning activities and teaching methods
Lecture, Practicum
Learning outcomes
The aim of the course is to acquire deeper knowledge in the field of analysis and monitoring metal forming technological processes. Student will get detailed information about methods and possibilities of scanning technical quantities involved in the process and outcome of the metal forming process. The principle, course and methodology of evaluation the basic destructive and non-destructive tests used in metal forming for evaluation material and technological properties of processing metals will be explained. Moreover, the importance of standardized and technological forming tests for technical practice will be explained as well. For typical representatives of materials designed for forming (deep-drawing steels and strength materials, Al alloys, corrosion-resistant materials, etc.) will be performed the focused experimental tests necessary for the definition of basic and advanced numerical deformation models used in the branch of metal forming. The education of course also familiarizes student´s knowledge in low-cycle and high-cycle fatigue testing of different types of materials and formed products. On the basis of performed experiments, mathematical approximations of the measured data will be explained and realized and examples of their further processing by the statistical hypothesis tests.

Prerequisites
unspecified

Assessment methods and criteria
Combined examination

Credit: 80% attendance, tests Exam: oral, only for students having credit, to prove knowledge from the discussed areas
Recommended literature
  • ČSN EN ISO 6892-1. Kovové materiály - Zkoušení tahem - Část 1: Zkušební metoda za pokojové teploty. Praha: Úřad pro technickou normalizaci, metrologii a státní zkušebnictví, 2011. 64 s. Třídící znak 420310..
  • JÁGROVÁ, J. a L. ČAPEK. Dynamická únosnost a životnost. Liberec: Technická univerzita v Liberci, 2014. ISBN 978-80-7494-135-1..
  • KUHN, H. A. a D. J. MEDLIN, ed. ASM HANDBOOK Volume 8 - Mechanical Testing and Evaluation. 10th ed. Materials Park: ASM International, 2000. ISBN 0-87170-389-0..
  • MACEK, K., HNILICA, F. a V. STARÝ. Experimentální metody v materiálovém inženýrství. Praha: Nakladatelství ČVUT, 2008. ISBN 978-80-01-03934-2..
  • MELOUN, M. a J. MILITKÝ. Kompendium statistického zpracování dat. Praha: Karolinum, 2012. ISBN 978-80-246-2196-8..
  • NEUBAUER, J., SEDLAČÍK, M. a O. KŘÍŽ. Základy statistiky: aplikace v technických a ekonomických oborech. 2., rozšířené vydání. Praha: Grada, 2016. ISBN 978-80-247-5786-5..
  • PHAM, H. Springer handbook of engineering statistics. London: Springer, 2006. ISBN 1-85233-806-7..
  • WILLIAMS, J. Engineering tribology. New York: Cambridge University Press, 2005. ISBN 0-521-60988-7..


Study plans that include the course
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