345-0352/03 – Forming, Casting and Welding Technologies (TTSaS)
| Gurantor department | Department of Mechanical Technology | Credits | 7 |
| Subject guarantor | prof. Ing. Radek Čada, CSc. | Subject version guarantor | prof. Ing. Radek Čada, CSc. |
| Study level | undergraduate or graduate | Requirement | Compulsory |
| Year | 1 | Semester | winter |
| | Study language | English |
| Year of introduction | 2016/2017 | Year of cancellation | 2019/2020 |
| Intended for the faculties | FS | Intended for study types | Bachelor |
Subject aims expressed by acquired skills and competences
Students will be able to:
• explain the basic concepts related to forming, casting and welding technologies,
• clarify the influence of forming on the properties and structure of the material,
• explain the basic laws of plastic deformation,
• describe the basic tools, machines and principles of hot forming, cold forming, material cutting, sheet metal drawing, bending, casting, unconventional forming, plastics processing, basic welding technologies, marking and calculation of welded joints and structures, weldability evaluation of materials and material cutting technology.
They will get:
• an overview of the principles and technical terminology of the main production methods – forming, casting and welding technologies,
• an overview of the basic technological processes of production used in engineering production, which is necessary for understanding modern production technologies.
They will be able to:
• choose suitable materials and master the methodology of creating technological procedures for the production of simple components, including basic calculations.
Teaching methods
Lectures
Individual consultations
Tutorials
Project work
Summary
Basic subject, in which the students will be acquainted with principles of main production methods – technologies of forming, casting and welding with due order technical terms. Subject contents tools, machines, choice of materials and method of creation of technologic production processes of simple parts included basic computations.
In subject the students will be acquainted with influence of forming upon properties and structure of materials, basic laws of plastic deformation, technologies of volume hot forming and cold forming, technologies of area shearing and blanking, accurate blanking, volume shearing, shearing of thin-walled sections and tubes, breaking, technologies of sheet-metal drawing, progressive drawing in strip, drawing with wall thinning, technologies of bending, casting, with casting sand mixtures, non-conventional forming technologies, plastic and their processing, basic welding technologies, marking and coputation of welded joints and constructions, evaluation of materials weldability and material cutting technologies
Compulsory literature:
Recommended literature:
[1] HOSFORD, W. F. Mechanical Behavior of Materials. 1. ed. United States of America, New York: Cambridge University Press, 2005. 425 s.
ISBN 0-521-84670-6. Signatura v ÚK VŠB-TUO: 263130, čárový kód: 3174138479, lokace: 345/Katedra mechanické technologie – deponát (nelze rezervovat).
[2] SEMIATIN, S. L. (volume editor) ASM Handbook: Volume 14B: Metalworking: Sheet Forming. United States of America, Materials Park: ASM International, 2006. 924 s.
ISBN 0-87170-710-1. Signatura v ÚK VŠB-TUO: 263020, čárový kód: 3174218354, lokace: volný výběr.
[3] SEMIATIN, S. L. (volume editor) ASM Handbook: Volume 14A: Metalworking: Bulk Forming. United States of America, Materials Park: ASM International, 2005. 888 s.
ISBN 0-87170-708-X. Signatura v ÚK VŠB-TUO: 263020, čárový kód: 3174138355, lokace: ÚK/FBI.
[4] HOSFORD, W. F. Materials for Engineers. 1. ed. United States of America, New York: Cambridge University Press, 2008. 278 s.
ISBN 978-0-521-89997-0. Signatura v ÚK VŠB-TUO: 271672, čárový kód: 3174204768, lokace: 9330/Centrum pokročilých inovačních technologií – deponát (nelze vypůjčit).
[5] DIETER, G. E. (volume editor) ASM Handbook: Volume 20: Materials Selection and Design: Handbook of Workability and Process Design. United States of America, Materials Park: ASM International, 1997. ISBN 0-87170-386-6.
[6] HOSFORD, W. F. Physical Metallurgy. 2nd ed. United States of America, Boca Raton: CRC Press, 2010. 423 s.
ISBN 978-1-4398-1360-7. Signatura v ÚK VŠB-TUO: 277881, čárový kód: 3174224669, lokace: volný výběr.
[7] HOULDCROFT, P and JOHN, R. Welding and Cutting: A Guide to Fusion Welding and Associated Cutting Processes. Velká Británie, Cambridge: Woodhead Publishing, 2001. 232 s.
ISBN 1-85573-578-4. Signatura v ÚK VŠB-TUO: 269510, čárový kód: 3174191604, lokace: volný výběr.
[8] LUNDH, H. Sheet Steel Forming Handbook: Size Shearing and Plastic Forming. 1st ed. Swedwn, Borlänge: SSAB Tunnplat AB, 1998, 1 sv. (různé stránkování). Signatura v ÚK VŠB-TUO: 255906, čárový kód: 3174084553, lokace: volný výběr.
[9] IŽDINSKÁ, Z. Metal Casting. 1. vyd. Slovenská republika, Bratislava: Slovenská technická univerzita, 2007. 112 s.
ISBN 978-80-227-2660-3. Signatura v ÚK VŠB-TUO: 266900, čárový kód: 3174180262 a 3174180263, lokace: volný výběr.
[10] IRWING, W. Continuous Casting of Steel. Velká Británie, London: Institute of Materials, 1993. 207 s.
ISBN 0-901716-53-7. Signatura v ÚK VŠB-TUO: 245498, čárový kód: 3174000204, lokace: sklad knih.
[11] NAUJOKS, W. and FABEL, D. C. Forging Handbook. United States of America, Cleveland: American Society for Metals, 1939, 630 s., [1] složená příloha. Signatura v ÚK VŠB-TUO: 74755, čárový kód: 3174065938 a 3174066755, lokace: sklad knih.
[12] ARSENAULT, R. Plastic Deformation of Materials. United States of America, New York: Academic Press, 1975. 504 s.
ISBN 0-12-341806-2. Signatura v ÚK VŠB-TUO: 133003, čárový kód: 3174057940, lokace: sklad knih.
[13] HEARN, E. Mechanics of Materials: An Introduction to the Mechanics of Elastic and Plastic Deformation of Solids and Structural Components. 2nd ed. Oxford: Pergamon Press, 1985. 913 s.
ISBN 0-08-030529-6. Signatura v ÚK VŠB-TUO: 205280, čárový kód: 3174045739, lokace: sklad knih.
[14] SEMIATIN, S. L. (volume editor) ASM Handbook: Volume 14: Forming and Forging. United States of America, Materials Park: ASM International, 1988. 978 s.
ISBN 0-87170-020-4. Signatura v ÚK VŠB-TUO: 251662, čárový kód: 3174043555, lokace: volný výběr (nelze objednat).
[15] GUY, A. G., BEVER, M., HENCH, L. L. and PETERLIN, A. Introduction to Materials Science. United States of America, New York: McGraw-Hill, 1971, 604 s. ISBN 07-025310-2. Signatura v ÚK VŠB-TUO: 115028, čárový kód: 3174199721, lokace: sklad knih.
[16] Modern Metal Cutting: A Practical Handbook. 1st English ed. Sandviken: Sandvik Coromant, 1994, 1 sv. (různé stránkování).
ISBN 91-972299-0-3. Signatura v ÚK VŠB-TUO: 245228, čárový kód: 3174064041, lokace: sklad knih.
[17] Techniques of Pressworking Sheet-metal: An Engineering Approach to Die Design. 1974.
ISBN 0-13900696-6. Signatura v ÚK VŠB-TUO: 113199, čárový kód: 3174240456, lokace: sklad knih.
[18] Metal Forming: The Application of Limit Analysis. 1980.
ISBN 0-8247-6847-7. Signatura v ÚK VŠB-TUO: 167954, čárový kód: 3174242091, lokace: sklad knih.
Way of continuous check of knowledge in the course of semester
Teaching methods:
• explanation of pedagogue at lectures with the use of photos, videos and films,
• utilization of script contained intuitive pictures and examples of technologic production processes of simple parts,
• explanation of pedagogue at practice,
• individual contracts for written projects, consultation with every student,
• sample of test pieces and parts,
• sample of some technologic production processes.
Criterii:
• technical and formal level of delivered written projects,
• knowledge of problematics at tests during practices.
E-learning
None.
Other requirements
Active attendance at exercises at least 80 %.
Mandatory tasks require at least 51 points.
Prerequisities
Subject has no prerequisities.
Co-requisities
Subject has no co-requisities.
Subject syllabus:
1) P1 – Influence of forming upon properties and structure of material, P2 – Basic laws of plastic strain,
2) P3 – Volume hot forming,
3) P4 – Flat shearing,
4) P5 – Accurate shearing,
5) P6 – Sheet-metal drawing, P7 – Drawing of non-rotary stampings,
6) P8 – Bending,
7) P9 – Casting, casting moulding mixtures,
8) P10 – Production documentation of casting, P11 – Production technological process of non-permanent raw mould for casting,
9) P12 – Volume cold forming,
10) P13 – Non-conventional forming methods, forming by high pressures and energies,
11) P14 – Polymers and their processing,
12) P1 – Basic terms of welding branch, P2 – Basic documentation of welding process,
13) P3 – Basic materials, P4 – Welding thermal cycle,
14) P5 – Materials weldability,
15) P6 – Welding technologies sorting,
16) P7 – Flame welding, P8 – Hand-operated arc welding by covered electrode,
17) P9 – Welding in protective atmospheres, P10 – Electric resistance welding,
18) P11 – Welding by automatic machine under melt, P12 – Thermal material cutting,
19) P13 – Welded joints defets, introduction to welding joints testing,
20) P14 – Soldering foundations.
QUESTIONS OF WRITTEN TEST FROM TECHNOLOGY, PART FORMING AND CASTING
A) Basic questions
1. State basic laws of plastic deformation and to every of them state brief description.
2. Describe influence of stress stage upon formability and deformation resistance, describe mechanical schemes of strain and stress.
3. Explain hardening curves, draw them for steel and explain their shape.
B) Die forging
1. State types of forming machines for forging and suitability of their utilization.
2. Explain main principles for choice of parting plane of forging and state, how the parting plane must be marked at forging drawing.
3. Describe what is the role and function of gutter, which variants of its design exist and when every particular variant is used.
4. Describe differences among blocking impression and finishing forging die cavity. State kinds of blocking impression cavities. Explain forging dies with more cavities.
5. Explain, what is ideal rough forging and how it can be constructed.
C) Cold volume forming of material
1. Explain required properties of steels for cold volume forming.
2. Draw schemes of cold upsetting, forward and backward extrusion, to every scheme state equations for calculation of proportional and logarithmic strain. Explain method of determination of hardening size after cold volume forming.
3. Explain purpose of phosphating of blanks for cold volume forming and describe, how the properties of initial material change after cold volume forming.
D) Shearing of sheet-metal
1. Explain, what is blanking plan, how it can be constructed, how its economy can be calculated.
E) Drawing of sheet-metal
1. Draw schemes of basic drawing operations.
2. Explain differences among sheets from killed and non-killed steels.
3. Describe method of determination of size of blank for drawing of cylindrical stampings.
4. State method of determination of number of draws at multioperational drawing of cylindrical stampings.
5. Explain importance of blankholder at drawing, shapes of blankholder for separate draws, what is effective surface of blankholder.
6. Draw schemes of drawing tools for 1st draw, 2nd draw and 3rd draw at drawing of cylindrical cup by three operations.
7. Describe why and in which cases at drawing of sheet-metal by more operations the heat-treatment between operations must be carried out.
F) Casting
1. Explain principles for choice of position of casting in mould, principles for determination of parting plane, how the parting plane must be marked at foundry procedure drawing.
2. Describe adjustments for decreasing of casting velocity of liquid metal.
3. Describe differences among casting from grey cast iron and from cast steel (shape of pouring basin, shapes of canals, using of risers, shrinkage, suitability of utilization).
4. Explain, when risers must be used, describe their function, principles for their design and location.
5. Describe, what is core, what kinds of them exist, in what and how they are produced, how they are put into mould, how they are marked at foundry procedure drawing.
6. Explain by simple example the foundry procedure drawing.
7. Describe process of production of sand mould for casting by manual moulding.
Conditions for subject completion
Conditions for completion are defined only for particular subject version and form of study
Occurrence in study plans
Occurrence in special blocks
Assessment of instruction
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