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Although the problem of tool design - involving both the selection of suitable geometry and material- has exercised the attention of metal forming engineers for as long as this industrial activity has existed, the approach to its solution has been generally that of the 'trial and error' variety. It is only relatively recently that the continuing expansion of the bulk metal-forming industry, combined with an increase in the degree of sophistication required of its products and processes, has focussed attention on the problem of optimisation of tool design. This, in turn, produced a considerable expansion of theoretical and practical investi gations of the existing methods, techniques r,nd concepts, and helped to systematise our thinking and ideas in this area of engineering activity. In the virtual absence, so far, of a single, encyclopaedic, but sufficien tly deep, summation of the state of the art, a group of engineers and materials scientists felt that an opportune moment had arrived to try and produce, concisely, answers to many tool designers' dilemmas. This book attempts to set, in perspective, the existing - and proven - concepts of design, to show their respective advantages and weaknesses and to indicate how they should be applied to the individual main forming processes of rolling, drawing, extrusion and forging.
Although the problem of tool design - involving both the selection of suitable geometry and material- has exercised the attention of metal forming engineers for as long as this industrial activity has existed, the approach to its solution has been generally that of the 'trial and error' variety. It is only relatively recently that the continuing expansion of the bulk metal-forming industry, combined with an increase in the degree of sophistication required of its products and processes, has focussed attention on the problem of optimisation of tool design. This, in turn, produced a considerable expansion of theoretical and practical investi gations of the existing methods, techniques r,nd concepts, and helped to systematise our thinking and ideas in this area of engineering activity. In the virtual absence, so far, of a single, encyclopaedic, but sufficien tly deep, summation of the state of the art, a group of engineers and materials scientists felt that an opportune moment had arrived to try and produce, concisely, answers to many tool designers' dilemmas. This book attempts to set, in perspective, the existing - and proven - concepts of design, to show their respective advantages and weaknesses and to indicate how they should be applied to the individual main forming processes of rolling, drawing, extrusion and forging.
The objective of this work is to develop a continuum sensitivity finite element analysis for the robust design of multi-stage metal forming processes in aircraft manufacturing. The computational forming design simulator being developed is applied to industrial forming design and provides the means to select the sequence of deformation processes, design the dies and preforms for each process stage as well as the process conditions such that a product is obtained with desired shape and microstructure and with the minimum material utilization and overall cost. The initial selection of the various processing stages are done a-priori and through the use of classification schemes operating on a digital materials and process library. This virtual process laboratory will assist the aircraft manufacturing industry in reducing time for process and product development, in trimming the cost of an extensive experimental process development effort and in developing processes for tailored material properties.
This book systematically introduces the principles of flexible forming technologies to manufacture thin-walled complex-shaped components, the mechanism of controlling the material flow, the design and the configuration of flexible forming technologies’ equipment and tools. It covers new technologies and new processes for forming hollow components, and relevant research on forming mechanisms, deformation laws, and defect control with examples from practical applications. It will be a useful reference for researchers, engineers, graduate and undergraduate students in aerospace, nuclear, railway, vehicle and petrochemical engineering, etc.
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.
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.
The numerical simulation of sheet metal forming processes has become an indispensable tool for the design of components and their forming processes. This role was attained due to the huge impact in reducing time to market and the cost of developing new components in industries ranging from automotive to packing, as well as enabling an improved understanding of the deformation mechanisms and their interaction with process parameters. Despite being a consolidated tool, its potential for application continues to be discovered with the continuous need to simulate more complex processes, including the integration of the various processes involved in the production of a sheet metal component and the analysis of in-service behavior. The quest for more robust and sustainable processes has also changed its deterministic character into stochastic to be able to consider the scatter in mechanical properties induced by previous manufacturing processes. Faced with these challenges, this Special Issue presents scientific advances in the development of numerical tools that improve the prediction results for conventional forming process, enable the development of new forming processes, or contribute to the integration of several manufacturing processes, highlighting the growing multidisciplinary characteristic of this field.
As the only comprehensive text focusing on metal shaping processes, which are still the most widely used processes in the manufacture of products and structures, Metal Shaping Processes carefully presents the fundamentals of metal shaping processes with their relevant applications. The treatment of the subject matter is adequately descriptive for those unfamiliar with the various processes and yet is sufficiently analytical for an introductory academic course in manufacturing. The text, as well as the numerous formulas and illustrations in each chapter, clearly show that shaping processes, as a part of manufacturing engineering, are a complex and interdisciplinary subject. The topics are organized and presented in such a manner that they motivate and challenge students to present technically and economically viable solutions to a wide variety of questions and problems, including product design. It is the perfect textbook for students in mechanical, industrial, and manufacturing engineering programs at both the Associate Degree and Bachelor Degree programs, as well a valuable reference for manufacturing engineers (those who design, execute and maintain the equipment and tools); process engineers (those who plan and engineer the manufacturing steps, equipment, and tooling needed in production); manufacturing managers and supervisors; product design engineers; and maintenance and reliability managers and technicians. Each chapter begins with a brief highlighted outline of the topics to be described. Carefully presents the fundamentals of the particular metal-shaping process with its relevant applications within each chapter, so that the student and teacher can clearly assess the capabilities, limitation, and potentials of the process and its competitive aspects. Features sections on product design considerations, which present guidelines on design for manufacturing in many of the chapters. Offers practical, understandable explanations, even for complex processes. Includes text entries that are coded as in an outline, with these numerical designations carried over the 320 related illustrations for easy cross-referencing. Provides a dual (ISO and USA) unit system. Contains end-of-chapter Review Questions. Includes a chapter on sheet metalworking covering cutting processes; bending process; tubes and pipe bending; deep drawing processes; other sheet metal forming process (stretch forming, spinning, rubber forming, and superplatic forming and diffusion bonding). Provides a useful die classification with 15 illustrations and description; presses for sheet metalworking; and high energy-rate forming processes. A chapter on nontraditional manufacturing process discusses such important processes as mechanical energy processes (ultrasonic machining, water jet cutting); electrochemical machining processes (electrochemical machining, electrochemical grinding); thermal energy processes (electric discharge processes, laser beam machining, electron beam machining); and chemical processes (chemical milling).
The design of extrusion forming tools (dies and calibrators) is a difficult task usually performed by the employment of experimental trial-and-error procedures, which can hinder the performance and cost of the tools, may increase the time to market of new extruded products and limit their complexity.This book provides detailed information on the design of extrusion forming tools. It describes the main problems to be faced when designing dies and calibrators, the most relevant polymer properties to be considered in the design process, the specific problems related to several types of conventional extrusion dies, and recent developments on the design of special dies and process modeling. It is an updated and unique book on the subject, where each chapter is prepared by internationally recognized experts. Having in mind its nature, it is expected to become a useful reference book for higher education students (both undergraduate and graduate ones), teachers, researchers and engineers active in the extrusion industry.