Worked Metal Forming Projects

This industrially oriented chapter develops, in readers, the skill of manufacturing machine components by using a sequence of metal forming operations with their complete engineering analyses. There are two metal forming projects in this chapter; project 1 involves bolt manufacturing, whereas project 2 deals with the manufacture of cups. Project 1 presents the description, the available material and equipment, the objectives/requirements, and, key solutions, including the determination of process parameters in extrusion, wire drawing, and upset forging. Project 2 describes the description, the available material and equipment, the objectives/requirements, and, key solutions, including calculations for rolling (including the calculation for rolling cost), shearing, blanking, and deep drawing. A process flow chart has also been developed for project 2 that presents the sequence of all operations involved in the cup manufacture with the changes in dimensions of the work after each step/operation. Finally, projects are given for practice.