Course syllabus
The course is offered by the department of Industrial and Materials Science.
To aim/purpose of the course is to introduce important manufacturing aspects of metal forming and joining.
All info regarding the course and handouts are uploaded to "Files".
Preliminary schedule (prel version 3)
Teacher abbreviations: JA Johan Ahlström, VA Vishnu Anilkumar, SV Satya Vaddamanu
|
Weekday |
Date |
Start |
End |
Room |
Content |
|
Monday |
2024-03-18 |
13:15 |
16:00 |
ML13 |
3h Course Intro, Forming Theory 1, JA |
|
Thursday |
2024-03-21 |
09:00 |
11:45 |
MB |
3h Forming Th 1 cont’d, Introduction to Joining, JA |
|
Thursday |
2024-03-21 |
15:15 |
17:00 |
MT11, MT12 |
2h Comsol Tutorial self-study |
|
Friday |
2024-03-22 |
15:15 |
17:00 |
MT11, MT12 |
2h Comsol Tutorial self-study |
|
Monday |
2024-03-25 |
13:15 |
16:00 |
ML13 |
3h Forming Process, JA |
|
Monday |
2024-04-08 |
13:15 |
16:00 |
ML13 |
3h Forming Theory 2, JA |
|
Thursday |
2024-04-11 |
08:30 |
11:45 |
VCC TK rec |
4h Volvo Cars study visit, Group A |
|
Thursday |
2024-04-11 |
15:15 |
17:00 |
MT11, MT12 |
2h Comsol Assignment Bending, SV |
|
Friday |
2024-04-12 |
15:15 |
17:00 |
MT11, MT12 |
2h Comsol Assignment Bending, SV |
|
Monday |
2024-04-15 |
13:15 |
16:00 |
ML13 |
3h Joining methods, Physics/Chemistry, JA |
|
Thursday |
2024-04-18 |
08:30 |
11:45 |
VCC TK rec |
4h Volvo Cars study visit, Group B |
|
Thursday |
2024-04-18 |
15:15 |
17:00 |
MT11, MT12 |
2h Comsol Assignment Bending, SV |
|
Friday |
2024-04-19 |
15:15 |
17:00 |
MT11, MT12 |
2h Comsol Assignment Bending, self-study |
|
Monday |
2024-04-22 |
13:15 |
16:00 |
ML13 |
3h Metallurgy of welding – Weld metal, JA |
|
Thursday |
2024-04-25 |
09:00 |
11:45 |
MB |
3h Metallurgy of welding – HAZ, JA |
|
Thursday |
2024-04-25 |
15:15 |
17:00 |
MT11, MT12 |
2h Heat Conduction Assignment, VA |
|
Friday |
2024-04-26 |
15:15 |
17:00 |
MT11, MT12 |
2h Heat Conduction Assignment, VA |
|
Thursday |
2024-05-02 |
09:00 |
11:45 |
MT11-12 |
Heat Conduction Assignment, VA |
|
Thursday |
2024-05-02 |
15:15 |
18:15 |
M1208A |
3x1h Weld Metallography lab sessions VA Please register on Canvas for your time slot |
|
Friday |
2024-05-03 |
15:15 |
17:00 |
MT11, MT12 |
2h Heat Conduction Assignment, self-study |
|
Monday |
2024-05-06 |
13:15 |
15:00 |
ML13 |
2h Introduction to NDT/NDE, JA |
|
Monday |
2024-05-13 |
13:15 |
17:00 |
ESAB |
4h ESAB study visit |
|
Thursday |
2024-05-16 |
09:00 |
11:45 |
- |
No lecture |
|
Thursday |
2024-05-16 |
15:15 |
17:00 |
MT11, MT12 |
2h Heat Conduction Assignment, self-study |
|
Friday |
2024-05-17 |
15:15 |
17:00 |
MT11, MT12 |
2h Heat Conduction Assignment, self-study |
|
Monday |
2024-05-20 |
13:15 |
16:00 |
ML13 |
3h Weld Defects and Weld Modelling, JA |
|
Thursday |
2024-05-23 |
09:00 |
11:45 |
MB |
3h Forming and Joining, JA |
TimeEdit Links to an external site.
Learning outcomes
After the course, the student should be able to:
- Outline basic principles of the most important methods for sheet metal forming and their relation to products and production including cost and sustainability aspects.
- Analyse and Discuss the influence of material properties and stress state on formability.
- Define and Compare the most common joining methods for metals, with focus on welding, and their relation to products and production including cost and sustainability aspects.
- Reason on the influence of underlying chemical and physical reactions on joining processes.
- Discuss cutting methods in the perspective to prepare for forming and welding processes.
- Explain the physical metallurgy of welding in important alloys and Judge weldability, phase transformations, microstructure and properties of welds and heat affected zones.
- Outline advanced weld simulation and Analyse important welding-induced effects on materials and components with simplified models.
- Discuss design and quality assurance of formed and welded components including typical defects, generation of internal stresses and their influence on mechanical properties.
Contents
Important forming and joining methods for sheet metal are covered. Influence of material properties on formability and welding are central. Underlying chemical and physical mechanisms and resulting effects like residual stresses and distortions are treated. Metal cutting methods are introduced. Quality assurance and evaluation of strength and defects in components are introduced.
Organisation and Structure
The course is organised with lectures, study visits, and practicals done in smaller teams. The course includes three practicals. The first practical is a computer assignment to illustrate spring-back in metal forming and give an idea about requirements in advanced forming simulations. The second is a computer assignment on heat conduction in fusion welding. The third practical is a laboratory exercise illustrating welding metallography. The course will be given entirely in English.
Prerequisites
The course requires knowledge from basic courses in materials science, solid mechanics and manufacturing technology. Especially materials science is crucial for the understanding of welding metallurgy. In case you are uncertain on these concepts, please read the following chapters in: Materials science and engineering: an introduction by William D. Callister, Jr. Chapters refer to Ed 7 (copies of different editions available at Chalmers library):
Diffusion, 5; Mech Prop. of Metals, 6; Mechanisms of Strengthening in Metals, 7.8-; Phase Diagrams, 9; Phase Transformations, 10; Thermal Processing 11.7-; Thermal Properties 19.
Literature and reading advice
The course is based on a book on forming provided on the course home page, and e-books on welding available via Chalmers library. Hand-outs of presentations will be provided on the course home page after each lecture. In some cases, brief excerpts from other books will be provided on the course home page.
Basically, everything that is brought up at the lectures and appears in the lecture handouts defines the core of the course content. The following reading advice is a complement to that. Generally, no specific values from tables or equations need to be learnt by heart; instead, focus on understanding!
Forming:
Formability - A Review of Parameters and Processes that Control, Limit or Enhance the Formability of Sheet Metal, Wilko C. Emmens, 2011
The book is available at the course home page.
Core content: Chs 3–7, 11, 20, 23. Less detailed: Chs 1–2, 8–10.
Plasticity and Bending
Hosford, W., & Caddell, R. (2011). Chs 1,2, 12. In Metal Forming: Mechanics and Metallurgy (pp. 17-29). Cambridge: Cambridge University Press. https://doi.org/10.1017/CBO9780511976940
Welding heat conduction:
Introduction to the Physical Metallurgy of Welding – Easterling, Elsevier, 1992
https://www.sciencedirect.com/book/9780750603942/introduction-to-the-physical-metallurgy-of-welding
Core content for heat conduction: Ch 1. Complementary material for weld metallurgy: Chs 2–3 and defects: Ch 4. Sufficient to read in Lippold, but many figures are taken from Easterling.
Welding processes:
Available as E-books through Chalmers Library.
Search for them and accept Knovel conditions for use.
The next time you want to access the books, the direct links below might work:
Welding Processes Handbook (2nd Edition) – Klas Weman, Woodhead Publishing, 2012
https://app.knovel.com/kn/resources/kpWPHE0001/toc
Core content: 1–2, 6–12, 16
Metallurgy of Welding, 6th Edition by J. F. Lancaster, 1999, Woodhead Publishing.
https://app.knovel.com/kn/resources/kpMWE00002/toc
Reference book, not central. Physics and Chemistry of welding, surface tension
Welding metallurgy and defects:
Welding Metallurgy and Weldability, John C. Lippold, John Wiley & Sons, Inc., 2015
https://dx.doi.org/10.1002/9781118960332
Core content on Weld metallurgy: Ch 2. Defects: Ch 3, Ch 4.3, Ch 4.5 (Generally: skip details if not touched upon in the lecture. Focus on steels and aluminium)
Practicals
The course includes three practicals:
P1: Metal Forming, modelling of spring-back Supervisor: Satya Vaddamanu
P2: Heat conduction computer assignment Supervisor: Vishnu Anilkumar
P3: Welding Metallography laboratory exercise Supervisor: Vishnu Anilkumar
For practicals P1 (numerical FE simulation using Comsol) and P2 (analytical computation using Matlab), please form teams of 2 students to solve the assignments and write the reports. It does not need to be the same group mates in P1 and P2. But be sure to choose teammates with a similar ambition regarding grade, since the grade on the reports will be weighted into the final grade of the course. Booking of teams are done on lists at Canvas. For P2 each team will receive individual parameter values. Computer simulations for both P1 and P2 are done in computer rooms in M-building, see schedule/TimeEdit.
For practical P3, the class will be divided into two groups: A and B, with separate time bookings. Within each group, you will form teams of 2 students working together by the microscope.
Reports are to be handed in according to instructions by each supervisor, but the typical time for hand in is one week after the last session, and the feedback should come within one week after submission. Please note that reports shall be concise and should not include general descriptions of methods etc. Reports for P1 and P2 must be submitted as attachments in pdf-format (not scanned) or MS Word-format (.doc /.docx) to the lab supervisors. Typical reports for P1 and P2 encompass some 10 pages, but most is in form of figures visualizing the results of the computations, i.e. graphs from Comsol or Matlab. Please note that any plagiarism (copied text etc) detected must be reported! The report for P3 is done as notes and sketches during the lab session, not graded.
Lecturers and student administration
Examiner and lecturer: Prof Johan Ahlström johan.ahlstrom@chalmers.se
Guest lecturer Forming: Dr Boel Wadman, RISE boel.wadman@ri.se
Lab coordinator: Vishnu Anilkumar visani@chalmers.se
Student Administration: Mrs Hanije Safakar hanije@chalmers.se
Course home page
Hand-outs from lectures, latest version of this document, news about lectures etc can be found on the course home page at URL: https://chalmers.instructure.com/courses/29008
Basic info on the course is available on the Study Portal: https://www.student.chalmers.se/sp/course?course_id=36527
Examination
The course will be assessed by project reports and a final written exam. The results of the parts will be weighted into a final grade. The written exam takes place on 30 May 2024 at 14.00–18.00 (re-exam according to Study Portal, not fixed to date). Make sure to register to the exam in due time according to what is written at the Student Portal. The exam is formulated in English, and only answers in English are accepted according to Chalmers rules for master’s programs. Permitted aids are a dictionary and a basic calculator. Except for the written exam, the laboratory exercises and computer assignments need to be attended and the reports accepted before a grade is given for the course.
- The grading of the forming assignment will constitute 10% of the final grade.
- The grading of the heat conduction assignment will constitute 10% of the final grade.
- The result of the exam will constitute 80% of the final grade.