Emg 4102 CN 1

DEDAN KIMATHI UNIVERSITY OF TECHNOLOGY
BSC MECHANICAL ENGINEERING
EMG 4102: MATERIAL FORMING PROCESSES
Preared By: PROF.. J. N. KERAITA

JANUARY 2021
SYLLABUS
EMG 4102 Material Forming Processes Year 4
Hours per Accreditatio Form of teaching Proof of
Week n Hours Lecture Exercise Practical Performance
6 6 2 1 3 Examination
Purpose
The purpose of this course is to enable the student to;
a. Understand shaping of metals and non-metallic materials
b. Understand plastic flow property of metal in various forming processes
c. Understand methods used in forming common polymer products
Learning outcomes
At the end of this unit the student should be able to:
a. Select appropriate methods for producing certain metal parts by cold and hot working.
b. Optimize parameters for producing metal parts by casting
c. Select forming methods for a range of plastics in common use and perform fabrication
of ceramics
Course description
Basic methods for shaping materials: overview.
Metal Forming: fundamental classification, cold and hot processes such as, shearing, bending
and deep drawing. Super elasticity.
Casting: fundamentals; types such as sand, die, centrifugal, investment and shell moulding.
Moulding; material. Melting equipment. Cast product; design, materials and defects; cleaning,
finishing and heat-treatment; quality control of casting. Polymer processing; physical and
chemical properties of polymers, injection, extrusion and blow moulding.
Ceramics: properties and fabrication. High speed metal forming; effects of high speed in
metal deformation; examples of sheet forming processes; water hammer forming; explosive
forming, electrodynamic forming, electromagnetic forming.
Prerequisites: EMG 2102 Workshop Processes & Practice II, EMG 2102 Engineering
Materials
Prescribed text books
1. Degarmo E. P., Roanld A. K. & Wayne A. (1988) Materials and Processes in
Manufacturing, Maxwell Macmillan Int, 7th ed.
2. Begeman M. L. & Amstead B. H. (1987) Manufacturing Processes, Wiley; New York,
8th Ed.
References:
1. Lindberg R. A. (1998) Processes and Manufacture of Materials, Prentice Hall of India,
4th Ed.
2. Brydson J. A. (1982) Plastics Materials, Butterworth-Heinemann Publishers, 7th Ed.
3. Heine R. W., Carl R. L. & Philip C. R. (1967) Principles of Metal Casting, McgrawHill,
New Delhi, 2nd Ed.
4. Journal of Manufacturing Science and Engineering
Teaching methodology: 2 hour lectures and 1 hour tutorial per week and at least three 3-
hour-laboratory sessions per semester organized on a rotational basis.
Instruction materials/equipment
1. Mechanical Engineering laboratories and workshop;
2. Overhead projector.
1
TEACHING TOPICS
1. Introduction and Overview
2. Fundamentals of Metal Forming
3. Casting of Metals
4. Fabrication of Ceramics
5. Fabrication of Polymers
6. High Speed Metal forming
EXAMINATION DISTRIBUTION
1. End of semester examination 70%
2. Assignments 05%
3. Laboratory 15%
4. Continuous Assessment Tests 10%
PURPOSE AND PREREQUISITES

 Understand methods of shaping of metals and non-metallic materials, including polymers.
 Understand plastic flow property
- Workshop Processes & Practice III

- 2201 Engineering Materials
- EMG 4106 Material Science - very important
Final year unit EMG 5113 Metal Forming Processes is mainly on detailed calculation of forces
and stresses.
Important!!
1. Describe the methods using sketches.
2. Hot or cold working?
3. Application to which group of materials and why?
4. Advantages and disadvantages.
OVERVIEW OF SHAPING OF MATERIALS

Basic Methods for Shaping Materials
Materials have to be processed into a great variety of shapes in order to make component parts of
every type. The shapes required vary enormously, both in size and complexity, ranging from
micro-electronic components to large castings and forgings of, perhaps, several hundred tones.
The engineer must have some awareness of the range of manufacturing processes available, and of
the advantages and limitations of the various processes. The properties of the material in the
finished component are also influenced to a considerable extent by the type of shaping process
employed, and by the conditions existing during processing. The whole range of shaping
processes can be very broadly classified into four categories:
 Casting; namely the pouring of liquid into prepared moulds.

 Manipulative processes; involving plastic deformation of the material.
 Powder techniques; in which a shape is produced by compacting a powder.
 Machining; cutting and grinding operations.
2
Most metallic materials are initially produced in the liquid phase and are then cast into shapes,
either to give a casting which may require only machining operations to be carried out on it before
sale, or into ingots which can be further processed by manipulative techniques such as rolling or
forging. Conditions during melting and casting are very important in determining the subsequent
quality of a metal or alloy and so a brief survey of some types of melting furnace is given before
the discussion of metal-casting processes.
Materials as Driving-force behind Technological Developments

History reveals that the driving force behind a successful technological revolution has been some
material. There would have been in fact (i) no industrial revolution without steel, and (ii) no
electronics/computer revolution without semiconductor. What would be the candidate materials of
the next technological development?
 Metals and Alloys: This will be based on improvement of their properties.
 Ceramics: These had been usually considered quite unimportant and suitable only for
manufacture of ceramic-jar, wash-basin and toilet-seat etc., now have changed completely.
Ceramics have now found several new applications ranging from electronics industry to
aero-space industry. Variety of ceramics, including glass have been developed which find
numerous applications.
 Plastics: Slowly but surely, plastic products are seeping into our house and finding more
and more applications in every walk of our life. Some people make a hue and cry
regarding environmental problems, but mostly these are baseless, as most of the plastics
can be recycled and reprocessed.
Therefore knowledge on how to process these materials is very important. Composites are also
coming in a big way and find applications ranging from a badminton racket to automobile and
aircraft industries. The base materials for the light weight composites are plastics (polymers) in
which high strength fibers are used as reinforcement. However composites are not unique
materials and their processing is largely not covered in this unit.
The diagram below shows the direct dependence and the various indirect dependences (Inverse,
Inter and Cross) among Materials, Manufacturing, Technological and Socioeconomic
Development.
END

Emg 4102 CN 1

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DEDAN KIMATHI UNIVERSITY OF TECHNOLOGY

BSC MECHANICAL ENGINEERING

EMG 4102: MATERIAL FORMING PROCESSES

Preared By: PROF.. J. N. KERAITA

PURPOSE AND PREREQUISITES

- Workshop Processes & Practice III

OVERVIEW OF SHAPING OF MATERIALS

 Casting; namely the pouring of liquid into prepared moulds.

Materials as Driving-force behind Technological Developments

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