Metal Forming

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.

Reflecting hands-on experience of materials, equipment, tooling and processes used in the industry, this work provides up-to-date information on flat-rolled sheet metal products. It addresses the processing and forming of light-to-medium-gauge flat-rolled sheet metal, illustrating the versatility and myriad uses of this material.

This publication has been written to honour the contribution to science and education made by the Distinguished Professor Emeritus Professor Schey on his eightieth birthday. The contributors to his book are among the countless researchers who have read, studied and learned from Professor Schey's work, which includes books, research monographs, invited papers, keynote papers, scientific journals and conferences. The topics include manufacturing, sheet and bulk metal forming and tribology, amongst others. The topics included in this book include: John Schey and value-added manufacturing; Surface finish and friction in cold-metal rolling; Direct observation of interface for tribology in metal forming; An examination of the coefficient of friction; Studies on micro plasto hydrodynamic lubrication in metal forming; Numerical simulation of sheet metal forming; Geometric and mechanics model of sheet forming; Modelling and optimisation of metal forming processes; The mathematical modelling of hot rolling steel; Identification of rheological and tribological parameters; Oxide behaviour in hot rolling; Friction, lubrication and surface response in wire drawing; and Modelling and control of temper rolling and skin pass rolling.

The introduction of numerical methods, particularly finite element (FE) analysis, represents a significant advance in metal forming operations. Numerical methods are used increasingly to optimize product design and deal with problems in metal forging, rolling, and extrusion processes. Metal Forming Analysis, first published in 2001, describes the most important numerical techniques for simulating metal forming operations. The first part of the book describes principles and procedures and includes numerous examples and worked problems. The remaining chapters focus on applications of numerical analysis to specific forming operations. Most of these results are drawn from the authors' research in the areas of metal testing, sheet metal forming, forging, extrusion, and similar operations. Sufficient information is presented so that readers can understand the nonlinear finite element method as applied to forming problems without a prior background in structural finite element analysis. Graduate students, researchers, and practising engineers will welcome this thorough reference to state-of-the-art numerical methods used in metal forming analysis.

The art of metal forming is an ancient one, as evidenced by the Greek and Roman helmets and cuirasses produced by the skill of early-day crafts- men. The wooden mallet, the metal hammer, and the leather sand bag used originally for hand forming of metals are still with us. With the advent of hand-operated machinery, a variety of hand brakes, benders, folders, rollers, crimpers, and rope-type drop hammers appeared and are still in use today. The development of power-driven machines brought out power hammers, power brakes, a multitude of presses, including hydraulic monsters (50,000 tons), wrappers, stretchers, steam and pneumatic hammers and the like. All are in use today in combination with tools and dies, some of which are rather sophisticated in nature. Some of the newer techniques of metal forming have been developed by the Manufacturing Engineering Laboratory of the Marshall Space Flight Center, and others by the aerospace industry companies.

Applied Metal Forming: Including FEM Analysis describes metal forming theory and how experimental techniques can be used to study any metal forming operation with great accuracy. For each primary class of processes, such as forging, rolling, extrusion, wiredrawing, and sheet-metal forming, it explains how FEA (Finite Element Analysis) can be applied with great precision to characterize the forming condition and in this way optimize the processes. FEA has made it possible to build very realistic FEM-models of any metal forming process, including complex three-dimensional forming operations, in which complex products are shaped by complex dies. Thus, using FEA it is now possible to visualize any metal forming process and to study strain, stresses, and other forming conditions inside the parts being manufactured as they develop throughout the process.

Different aspects of metal forming, consisting of process, tools and design, are presented in this book. The chapters of this book include the state of art and analysis of the processes considering the materials characteristics. The processes of hydroforming, forging and forming of sandwich sheet are discussed. Also, a chapter on topography of tools, and another chapter on machine tools are presented. Design of a programmable metal forming press and methods for predicting forming limits of sheet metal are described.