Sheet Metal Forming Lab

Faculty-In-Charge

Lab Overview

The lab is developed to learn the fundamental techniques for shaping metal sheets using stretch forming, stamping, and drawing operations. Hands-on practice with equipment like presses, dies, emphasizing safety protocols and proper tool handling. The lab also focus on material properties, formability characterization studies depending on process parameters, and quality control to ensure precision and minimize defects. The lab integrates practical applications and troubleshooting skills to prepare individuals for real-world manufacturing challenges.

Key Research Areas

Hot forming: improving formability of lightweight aluminum alloy sheets, FSW sheets
Formability window: identifying formability limits while stamping under different process parameters
Material Properties and Behavior: Understanding mechanical properties of materials affect formability.
Tooling and Die Design: Improving the design and performance of tooling and dies used in forming processes.
Defect Detection and Prevention: identifying and mitigating defects such as fracture, wrinkling, tearing, and distortion
Simulation and Modeling: using FE methods to predict material behavior, process outcomes, and optimize forming techniques.

Significant Facilities & Special Features

Customized tooling to perform high temperature forming
Hydraulic bulge testing facility
Computational facility- High performance workstations
ANSYS-LSDYNA license (500 Core)
Electrochemical Circular Grid Marking machine
Laser displacement sensors, 12 channel DAQ

Major Equipment

Hydraulic press capable of performing stretch forming and deep drawing under controlled blank holding pressures
DAQ system (NI) for accurate measurement of displacement through laser sensor
Provision to modify tools to accommodate heating arrangements
2 DELL workstations with higher specs to perform modeling and numerical simulations

Research Funding & Grants

Development of E-HFQ process for precision manufacturing of automotive body components using high-strength aluminum alloy sheets, SERB-SRG, 20.82 Lakhs, Jan 2024 (2 years)
Evaluation of elevated temperature fracture forming limit diagram of heat treatable aluminum alloy sheets, BITS Pilani -ACG, 10.00 Lakhs, Nov 2022 (2 years)
Investigation of formability of tailor welded aluminum blanks during elevated temperature incremental sheet forming process, BITS Pilani - RIG, 2.00 Lakhs, Jul 22 (2 years)

Achievements

Publications:

Effect of Material Modeling on Prediction of Isothermal Formability of AA6082-O Sheet at Elevated Temperature. 2024 (Accepted)
Crushing Performance of AA5754 and AA6082 Shells Fabricated by Warm Redrawing Process. J. Mat. Engg. Perf. (2023) https://doi.org/10.1007/s11665-023-08581-2

Integrated First Degree

Higher Degree

Doctoral Programmes

WILP

Dubai Campus

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