Manufacturing, reduced to its simplest form, involves the sequencing of product forms through a number of different processes. Each individual step, known as an unit manufacturing process, can be viewed as the fundamental building block of a nation's manufacturing capability. A committee of the National Research Council has prepared a report to help define national priorities for research in unit processes. It contains an organizing framework for unit process families, criteria for determining the criticality of a process or manufacturing technology, examples of research opportunities, and a prioritized list of enabling technologies that can lead to the manufacture of products of superior quality at competitive costs. The study was performed under the sponsorship of the National Science Foundation and the Defense Department's Manufacturing Technology Program.
As part of the Metalworking Processes and Equipment Program, information was collected on deformation characteristics of metals and their effect on processing operations. The report presents the information collected from technical engineering reports on Government contracts and from general engineering and metallurgical publications. The objective is to help the nonspecialist in recognizing the implications of scientific findings and in applying them in specific operations. This report contains a series of articles covering the following subjects: Ductile Fracture; Application of High Pressure to the Forming of Brittle Metals; Superplasticity; Lubrication in Metal-Deformation Processes; Swaging; Adiabatic Conditions in Deformation Processing; Residual Stresses produced by Deformation. These subjects are treated in two ways: (1) generalized discussions of common processes point out why specific variables must be modified in order to deform certain types of metals satisfactorily; and (2) data on the more difficult-to-form metals are used to illustrate the principles, limitations, and effects of the processes. (Author).
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).
As part of the Metalworking Process and Equipment Program, a survey was conducted to collect and summarize information on deformation characteristics of metals and their effect on processing operations. This report presents information obtained from reports on Governmentsponsored work and from articles in technical publications. The report covers eight subjects: extrusion, forging, rolling, thermal mechanical variables affecting the properties of refractory metals and alloys, development of preferred orientations, anisotropy of strength and ductility, high-strain-rate deformation, and strain aging. In order to be useful to engineering students and production engineers the topics are treated in two ways. Generalized discussions of common processes point out why specific variables must be modified in order to deform certain types of metals satisfactorily. When practical, data on the more-difficultto-form metals are used to illustrate the principles, limitations, and effects of the processes. The objective is to help the non-specialist recognize the implications of specific findings and to apply them to specific operations. (Author).
On October 3, 1963, a symposium was sponsored by the Bureau of Naval Weapons, Metalworking Processes and Equipment Program, on the application of high pressure in metal-deformation processing. Past research has shown that superimposed hydrostatic pressure can significantly increase the ductility at fracture of various materials. These observations have stimulated considerable interest in applying this hydrostatic-pressure effect to metal deformation processing, where it was anticipated that improved ductility and fabricability of brittle materials could be realized. Hydrostatic extrusion and hydrodynamic compressive forging were two such fabrication techniques discussed at the symposium, and preliminary results were found to be encouraging. Another fabrication process that will be investigated in the near future is sheet drawing, where the effect of superimposed pressure improves the ductility to fracture, it was noted that pressure cycling did not improve either the strength or ductility of steels containing various amounts of carbon. In addition to the mechanical-property effects, hydrostatic pressure has been found to affect measurably, numerous metallurgical properties of metals and alloys. (Author).
Briefly reviews the basic principles of metal forming but major emphasis is on the latest developments in the design of metal-forming operations and tooling. Discusses the position of metal forming in manufacturing and considers a metal-forming process as a system consisting of several interacting variables. Includes an overall review and classification of all metal-forming processes. The fundamentals of plastic deformation - metal flow, flow stress of metals and yield criteria - are discussed, as are significant practical variables of metal- forming processes such as friction, temperatures and forming machines and their characteristics. Examines approximate methods of analyzing simple forming operations, then looks at massive forming processes such as closed-die forging, hot extrusion, cold forging/ extrusion, rolling and drawing (discussion includes the prediction of stresses and load in each process and applications of computer-aided techniques). Recent developments in metal-forming technology, including CAD/CAM for die design and manufacture, are discussed, and a review of the latest trends in metal flow analysis and simulations.
As part of the Metalworking Process and Equipment Program, a survey was conducted to collect and summarize information on deformation characteristics of metals and their effect on processing operations. This report presents information obtained from reports on Governmentsponsored work and from articles in technical publications. The report covers eight subjects: extrusion, forging, rolling, thermal mechanical variables affecting the properties of refractory metals and alloys, development of preferred orientations, anisotropy of strength and ductility, high-strain-rate deformation, and strain aging. In order to be useful to engineering students and production engineers the topics are treated in two ways. Generalized discussions of common processes point out why specific variables must be modified in order to deform certain types of metals satisfactorily. When practical, data on the more-difficultto-form metals are used to illustrate the principles, limitations, and effects of the processes. The objective is to help the non-specialist recognize the implications of specific findings and to apply them to specific operations. (Author).
Having a good understanding of a construction material’s performance under different conditions is essential for helping engineers in selecting the right type of material for a job and for setting design specifications. Keeping abreast of the latest research is an important part of this. The deformation and processing of structural materials is divided into eight chapters, each one exploring a material’s processing and deformation behaviour. They also consider how the microstructural composition of materials is affected by processing and what influence this has on its subsequent in situ performance. The materials and behaviours looked at in the chapters include: aluminium and its alloys; magnesium alloys; ferrous alloys; superalloys (Ni-based alloys); semisolid metal (SSM) processing of metallic alloys; plastic deformation of intermetallic alloys; metal matrix composites (MMCs); and fine grain superplasticity in SP materials. The first of its kind to give comprehensive coverage to the subject, The deformation and processing of structural materials is a valuable resource for engineers, researchers in mechanical, civil and structural engineering. Contains research on the preformance of materials Valuable resource for researchers in mechanical, civil and structural engineering Comprehensive coverage to the deformation and processing of all types of structural materials
The Army Materials and Mechanics Research Center has con ducted the Sagamore Army Materials Research Conference in coop eration with the Materials Science Group of the Department of Chemical Engineering and Materials Science of Syracuse University since 1954. The purpose of the conference has been to gather to gether scientists and engineers from academic institutions, in dustry and government who are uniquely qualified to explore in depth a subject of importance to the Army, the Department of Defense and the scientific community. This volume, Advances in Deformation Processing, addresses the areas of Analytical Advances, Workability, Processing to Optimize Properties, Advanced Applications - Materials, and Advanced Applications - Processes. The dedicated assistance of Mr. Joseph Bernier of the Army Materials and Mechanics Research Center throughout the stages of the conference planning and finally the publication of the Sagamore Conference Proceedings is deeply appreciated. The support of Helen Brown DeMascio of Syracuse University in p- paring the final manuscript is acknowledged. The continued active interest and support of these conferences by Dr. A. E. Gorum, Director of the Army Materials and Mechanics Research Center, is appreciated. Syracuse University Syracuse, New York The Editors vii Contents SESSION I INTRODUCTION A. E. Gorum, Moderator Continuum Mechanics and Deformation Processing 1.
