• TDMT3111
  • Tool Design & Metal Forming

  • Credits (ECTS): 5
  • Mechanical and Design Engineering
  • Available on Programme(s): DT023

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Module Description

Knowledge Breadth: This module will embrace the topics of metal cutting and forming [1], [2], [4], [5], [6], [7] and in addition the topic of geometric tolerancing of assemblies and mechanisms [3]. Kind The type of knowledge appropriate to this module is primarily concerned with value creating metal forming processes in primary metalworking industries [1], [2], [3], [4], [5], [6], [7]. Know-how and skill Range This module will introduce the learner to a broad range of skills [1], [2], [3], [4], [5], [6], [7], that will enhance their capabilities as applied to increasing the effectiveness and efficiency of metal cutting and forming processes and the geometric tolerancing of assemblies and mechanisms. Selectivity The learner will be capable of differentiating between the central themes of the module and choosing the most appropriate element of the module to apply in the particular context required. Competence Context The learner will be able to apply their knowledge and skills in a wide range of organisations, whether primary metal cutting and forming industries, or industries that use the products of such primary industries. Role The student will be competent to execute multiple roles [[1], [2], [3], [4], [5], [6], [7], in various organisations, as either an individual or as a member of a team. Learning to learn During the course of the module the learner will be expected to read additional material in standard texts and internet based research material. Insight During the course of the module, the learner will have been introduced to various models of metal cutting and forming processes and geometric tolerancing systems, and will have applied these models during the class and during independent study. This will lead to an understanding of the model behaviour, and will allow the learner to predict the behaviour of various metal forming and cutting processes in specific instances[1], [2], [3], [4], [5], [6], [7].

Module Aims

The aim of this module is to: Provide a fundamental description of metal cutting and forming technology Demonstrate basic CNC programming techniques Give a practical overview of press and form tool design Highlight the importance of theories of failure in the study of plastic flow of metals Give an appreciation of the effects of changes within the microstructure on the macrostructure of metals Provide an overview technology and risks associated with metal forming equipment Present a general introduction geometric tolerancing

Indicative Syllabus

Commercial testing of sheet metals:
Geometric tolerancing:
Layout and design techniques for fixed configuration press tools. Determination of forces required to cut given geometric profiles, methods of force reduction. Methods of moment balancing. Tool configuration for CNC punch presses, description of and advantages of CNC punch presses, CNC punch pressing techniques, CNC press programming, sheet metal CNC punch press practical laboratory.
Metal bending, description of tooling / end effectors used in metal air bending and coining. Description of press brakes and associated technology, including CNC control. Determination of forces to initiate bending in specific circumstances. Bend allowance and bend deduction, determination of part profiles. Metal forming, including method of determination of blank diameters and press forces for specific geometry. Metal forming tool configurations.
Metal cutting technology:
Metal forming technology:
Plastic ratio, grid circle analysis, forming limit diagrams, commercial tests.
Purpose of geometric tolerancing systems, comparison and contrast of standard dimensional tolerancing with true position system. Fixed and floating fastener methods, determination of required hole and fastener dimensions.
Review of causes of work hardening in metals. Fundamentals of plasticity, including plastic instability. Use of theories of failure in determination of onset of yield. The true stress - true strain curve, strength co-efficient k and work hardening coefficient n. Models of elasto-plastic behaviour.
Work hardening of metals:

Total Contact Teaching Hours:36
Class Size:30

Please note that the catalogue is provided as a guide to modules in DIT. Not all modules listed will necessarily be offered every year and new modules may also be added. Information subject to change. For detail on specific programmes/modules please contact the relevant School directly.