Applied Metal Forming

A professional reference for advanced courses in two of the most common manufacturing processes: metal forming and metal cutting.

Micro Metal Forming, i. e. forming of parts and features with dimensions below 1 mm, is a young area of research in the wide field of metal forming technologies, expanding the limits for applying metal forming towards micro technology. The essential challenges arise from the reduced geometrical size and the increased lot size. In order to enable potential users to apply micro metal forming in production, information about the following topics are given: tribological behavior: friction between tool and work piece as well as tool wear mechanical behavior: strength and formability of the work piece material, durability of the work pieces size effects: basic description of effects occurring due to the fact, that the quantitative relation between different features changes with decreasing size process windows and limits for forming processes tool making methods numerical modeling of processes and process chains quality assurance and metrology All topics are discussed with respect to the questions relevant to micro metal forming. The description comprises information from actual research and the young history of this technology branch to be used by students, scientists and engineers in industry who already have a background in metal forming and like to expand their knowledge towards miniaturization. tribological behavior: friction between tool and work piece as well as tool wear mechanical behavior: strength and formability of the work piece material, durability of the work pieces size effects: basic description of effects occurring due to the fact, that the quantitative relation between different features changes with decreasing size process windows and limits for forming processes tool making methods numerical modeling of processes and process chains quality assurance and metrology All topics are discussed with respect to the questions relevant to micro metal forming. The description comprises information from actual research and the young history of this technology branch to be used by students, scientists and engineers in industry who already have a background in metal forming and like to expand their knowledge towards miniaturization.

- Overview of materials and treatment aspects of manufacturability of sheet metal - Written by an industrial expert turned scientist - Concentrates on the formability of sheet metal, one of the fundamental form material is used in metalworking

Ductile Fracture in Metal Forming: Modeling and Simulation examines the current understanding of the mechanics and physics of ductile fracture in metal forming processes while also providing an approach to micromechanical ductile fracture prediction that can be applied to all metal forming processes. Starting with an overview of different ductile fracture scenarios, the book then goes on to explain modeling techniques that predict a range of mechanical phenomena that can lead to ductile fracture. The challenges in creating micromechanical models are addressed alongside methods of applying these models to several common metal forming processes. This book is suitable for researchers working in mechanics of materials, metal forming, mechanical metallurgy, and plasticity. Engineers in R&D industries involved in metal forming such as manufacturing, aerospace, and automation will also find the book very useful. Explains innovative micromechanical modeling techniques for a variety of material behaviors Examines how these models can be applied to metal forming processes in practice, including blanking, arrowed cracks in drawing, and surface cracks in upset forging Provides a thorough examination of both macroscopic and microscopic ductile fracture theory

The intention of this book is to reveal and discuss some aspects of the metal fo- ing plasticity theory. The modern theory describes deformation of metallic bodies in cold and hot regimes under combined thermal and mechanical loadings. Th- mal and deformation fields appear in metal forming in various forms. A thermal field influences the material properties, modifies the extent of plastic zones, etc. and the deformation of metallic body induces changes in temperature distribution. The thermal effects in metal forming plasticity can be studied at two levels, - pending on whether uncoupled or coupled theories of thermo-plastic response have to be applied. A majority of metal forming processes can be satisfactorily studied within an uncoupled theory. In such an approach the temperature enters the stress-strain relation through the material constants and through the thermal dilatation. The description of thermo-plastic deformation in metal forming is c- ried out on the ground of thermodynamics.

Written by authorities in the subject, this book provides a complete treatment of metal forming and machining by using the computational techniques FEM, fuzzy set theory and neural networks as modelling tools. The algorithms and solved examples included make this book of value to postgraduates, senior undergraduates, and lecturers and researchers in these fields. Research and development engineers and consultants for the manufacturing industry will also find it of use.

This 2001 book describes the most important numerical techniques for simulating metal forming operations.