Design And Development Of Metal Forming Processes And Products Aided By Finite Element Simulation

This book presents state-of-the-art research on forming processes and formed metal product development aided by the Finite Element Method (FEM). Using extensive and informative illustrations, tables and photographs, it systematically presents real-life case studies and established findings regarding various forming processes and methods aided by FEM simulation, and addresses various issues related to metal formed part design, process determination, die design and die service life analysis and prolongation, as well as product quality assurance and improvement. Metal forming has been widely used in many industries. This traditional manufacturing process, however, has long been linked to many years of apprenticeship and skilled craftsmanship, and its conventional design and development paradigm appeared to involve more know-how and trial-and-error than in-depth scientific calculation, analysis and simulation. The design paradigm for forming processes and metal formed product development thus cannot meet the current demands for short development lead-times, low production costs and high product quality. With the advent of numerical simulation technologies, the design and development of forming processes and metal formed products are carried out with the aid of FEM simulation, allowing all the potential design spaces to be identified and evaluated, and the best design to ultimately be determined and implemented. Such a design and development paradigm aims at ensuring “designing right the first time” and reducing the need for trial-and-error in the workshop. This book provides postgraduates, manufacturing engineers and professionals in this field with an in-depth understanding of the design process and sufficient knowledge to support metal formed part design, forming process determination, tooling design, and product quality assurance and control via FEM simulation. “/p>

The application of computer-aided design and manufacturing techniques is becoming essential in modern metal-forming technology. Thus process modeling for the determination of deformation mechanics has been a major concern in research . In light of these developments, the finite element method--a technique by which an object is decomposed into pieces and treated as isolated, interacting sections--has steadily assumed increased importance. This volume addresses advances in modern metal-forming technology, computer-aided design and engineering, and the finite element method.

Metal Forming: Formability, Simulation, and Tool Design focuses on metal formability, finite element modeling, and tool design, providing readers with an integrated overview of the theory, experimentation and practice of metal forming. The book includes formability and finite element topics, including insights on plastic instability, necking, nucleation and coalescence of voids. Chapters discuss the finite element method, including its accuracy, reliability and validity and finite element flow formulation, helping readers understand finite element formulations, iterative solution methods, friction and contact between objects, and other factors. The book's final sections discuss tool design for cold, warm and hot forming processes. Examples of tools, design guidelines, and information related to tool materials, lubricants, finishes, and tool failure are included as well. Provides fundamental, integrated knowledge on metal formability, finite element topics and tool design Outlines user perspectives on accuracy, reliability and validity of finite element modeling Discusses examples of tools, their design guidelines, tool lubricants, and tool failure Considers the role played by stress triaxiality and shear and introduces uncoupled ductile damage criteria Includes applications, worked examples and detailed techniques

Manufacturing industries strive to improve the quality and reliability of their products, while simultaneously reducing production costs. To do this, modernized work tools must be produced; this will enable a reduction in the duration of the product development cycle, optimization of product development procedures, and ultimately improvement in the productivity of design and manufacturing phases. Numerical simulations of forming processes are used to this end, and in this book various methods and models for forming processes (including stamping, hydroforming and additive manufacturing) are presented. The theoretical and numerical advances of these processes involving large deformation mechanics on the basis of large transformations are explored, in addition to the various techniques for optimization and calculation of reliability. The advances and techniques within this book will be of interest to professional engineers in the automotive, aerospace, defence and other industries, as well as graduates and undergraduates in these fields.

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.

The book presents a compilation of research on meso/microforming processes, and offers systematic and holistic knowledge for the physical realization of developed processes. It discusses practical applications in fabrication of meso/microscale metallic sheet-metal parts via sheet-metal meso/microforming. In addition, the book provides extensive and informative illustrations, tables, case studies, photos and figures to convey knowledge of sheet-metal meso/microforming for fabrication of meso/microscale sheet-metal products in an illustrated manner. Key Features • Presents complete analysis and discussion of micro sheet metal forming processes • Guides reader across the mechanics, failures, prediction of failures and tooling and prospective applications • Discusses definitions of multi-scaled metal forming, sheet-metal meso/microforming and the challenges in such domains • Includes meso/micro-scaled sheet-metal parts design from a micro-manufacturability perspective, process determination, tooling design, product quality analysis, insurance and control • Covers industrial application and examples

Deformation Based Processing of Materials: Behavior, Performance, Modeling and Control focuses on deformation based process behaviors and process performance in terms of the quality of the needed shape, geometries, and the requested properties of the deformed products. In addition, modelling and simulation is covered to create an in-depth and epistemological understanding of the process. Other topics discussed include ways to efficiently reduce or avoid defects and effectively improve the quality of deformed parts. The book is ideal as a technical document, but also serves as scientific literature for engineers, scientists, academics, research students and management professionals involved in deformation based materials processing. Covers process behaviors, such as non-uniform deformation, unstable deformation, material flow phenomena, and process performance Includes modelling and simulation of the entire deformation process Looks at control of the preferred deformation, undesirable material flow, avoidance and reduction of defects, and improving the dimensional accuracy, surface quality and microstructure construction of the produced products

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