An alternative method of teaching the mechanics of bulk metal forming to undergraduates: Newtonian and Lagrangian approaches

An alternative method of teaching the mechanics of bulk metal forming to undergraduate students is presented. This method has been practiced by us at the University of Florida, Gainesville, FL, USA, and at Mahindra University, Hyderabad, India. Certain key factors differentiate it from the procedures employed in standard textbooks. The relevant fundamental background is laid, emphasizing the materials science and solid mechanics aspects that govern the analysis of all bulk metal forming operations. In this unique approach, we avoid usage of empirical expressions completely and analyse processes from first principles. At the same time, we refrain from rigorous mathematical descriptions which may distract the undergraduate engineering student. Using both the energy balance (Lagrangian) and the force balance (Newtonian) methods, we analyse representative bulk forming processes. An illustrative example enables students to appreciate the comparative orders of magnitude of specific forces encountered in different processes. We present tested methods that helped students to appreciate the ease with which a large number of seemingly unrelated processes can be understood and analyzed. We have used this presentation as the standalone lecture material while teaching the topic. It has helped students to avoid the burden of using multiple reference textbooks to gain an understanding of the mechanics of bulk forming processes.