Design and Development of Metal-Forming Processes and Products Aided by Finite Element Simulation

Design and Development of Metal-Forming Processes and Products Aided by Finite Element Simulation PDF

Author: Ming Wang Fu

Publisher: Springer

Published: 2016-10-22

Total Pages: 258

ISBN-13: 3319464647

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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>

Metal Forming and the Finite-Element Method

Metal Forming and the Finite-Element Method PDF

Author: the late Shiro Kobayashi

Publisher: Oxford University Press

Published: 1989-03-09

Total Pages: 398

ISBN-13: 0195364570

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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

Metal Forming PDF

Author: Chris V. Nielsen

Publisher: Academic Press

Published: 2021-02-12

Total Pages: 430

ISBN-13: 0323852564

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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

Modeling of Metal Forming and Machining Processes

Modeling of Metal Forming and Machining Processes PDF

Author: Prakash Mahadeo Dixit

Publisher: Springer Science & Business Media

Published: 2008-05-14

Total Pages: 599

ISBN-13: 1848001894

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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.

Modelling and Simulation of Sheet Metal Forming Processes

Modelling and Simulation of Sheet Metal Forming Processes PDF

Author: Marta C. Oliveira

Publisher: MDPI

Published: 2020-04-22

Total Pages: 254

ISBN-13: 3039285564

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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.

Material Forming Processes

Material Forming Processes PDF

Author: Bouchaib Radi

Publisher: John Wiley & Sons

Published: 2016-09-16

Total Pages: 272

ISBN-13: 1119361397

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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.

Modelling of Metal Forming Processes

Modelling of Metal Forming Processes PDF

Author: J.L. Chenot

Publisher: Springer Science & Business Media

Published: 2012-12-06

Total Pages: 343

ISBN-13: 9400914113

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The physical modelling of metal forming processes has been widely used both in University and in Industry for many years. Relatively simple numerical models, such as the Slab Method and the Upper Bound Method, were first used and many such models are implemented in the industry for practical design or regulation of forming processes. These are also under investigation in the University, mainly for treat models ments which require low cost calculations or very fast answers for on-line integration. More recently, sophisticated numerical methods have been used for the simulation of metal flow during forming operations. Since the early works in 1973 and 1974, mainly in U. K. and U. S. A. , the applications of the finite element method to metal processing have been developed in many laboratories all over the world. Now the numerical approach seems to be widely re cognized as a powerful tool for comprehension oriented studies, for predic ting the main technological parameters, and for the design and the optlmi zation of new forming sequences. There is also a very recent trend for the introduction of physical laws in the thermo-mechanical models, in order to predict the local evolution of internal variable representing the micro structure of the metal. To day more and more practicians of the Industry are asking for compu ter models for design of their forming processes.

Sheet Metal Forming Processes

Sheet Metal Forming Processes PDF

Author: Dorel Banabic

Publisher: Springer Science & Business Media

Published: 2010-06-21

Total Pages: 312

ISBN-13: 3540881131

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The concept of virtual manufacturing has been developed in order to increase the industrial performances, being one of the most ef cient ways of reducing the m- ufacturing times and improving the quality of the products. Numerical simulation of metal forming processes, as a component of the virtual manufacturing process, has a very important contribution to the reduction of the lead time. The nite element method is currently the most widely used numerical procedure for s- ulating sheet metal forming processes. The accuracy of the simulation programs used in industry is in uenced by the constitutive models and the forming limit curves models incorporated in their structure. From the above discussion, we can distinguish a very strong connection between virtual manufacturing as a general concept, ?nite element method as a numerical analysis instrument and constitutive laws,aswellas forming limit curves as a speci city of the sheet metal forming processes. Consequently, the material modeling is strategic when models of reality have to be built. The book gives a synthetic presentation of the research performed in the eld of sheet metal forming simulation during more than 20 years by the members of three international teams: the Research Centre on Sheet Metal Forming—CERTETA (Technical University of Cluj-Napoca, Romania); AutoForm Company from Zürich, Switzerland and VOLVO automotive company from Sweden. The rst chapter presents an overview of different Finite Element (FE) formu- tions used for sheet metal forming simulation, now and in the past.

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