Metal Forming and Impact Mechanics reviews significant developments concerning the mechanics of metal forming and impact. Topics covered include the kinematics of steady plane flows in elastoplastic media; contact zone and friction coefficient in hot-rolling; and plastic deformation of porous materials. Developments in the use of superplastic alloys, the use of metal tubes as impact energy absorbers, and fracturing of explosively loaded solids are also discussed. This book has 18 chapters divided equally between the broad headings of metal forming and impact mechanics. The section on metal forming mechanics includes papers that explore an upper bound approach to metal forming processes; rotary forming of rings under kinematic constraints; and microcomputer programs for rolling and extrolling. The section on impact mechanics examines the use of elementary approximation techniques to study plastic deformation in pulse loaded structures; static and dynamic axial crushing of circular and square tubes; and shear-control fragmentation of explosively loaded steel cylinders. This monograph will be of value to structural and mechanical engineers, metallurgists, and materials scientists and technologists, as well as to those active in the field of solid mechanics.
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.
By an engineer with decades of practical manufacturing experience, this book is a complete modern guide to sheet metal forming processes and die design - still the most commonly used methodology for the mass-production manufacture of aircraft, automobiles, and complex high-precision parts. It illustrates several different approaches to this intricate field by taking the reader through the "hows" and "whys" of product analysis, as well as the techniques for blanking, punching, bending, deep drawing, stretching, material economy, strip design, movement of metal during stamping, and tooling. While concentrating on simple, applicable engineering methods rather than complex numerical techniques, this practical reference makes it easier for readers to understand the subject by using numerous illustrations, tables, and charts. Emphasizes the influence of materials as an aid to understanding manufacturing processes and operations. Features the essential mathematical formulas and calculations needed for various die operations and performance evaluation. Shows the comparative advantages and liabilities for each manufacturing process and operation. Offers a complete picture of the knowledge and skills needed for the effective design of dies for sheet-metal forming processes highlighted with illustrative examples. Provides properties and typical applications of selected tool and die materials for various die parts.
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).
This book is intended to serve as core text or handy reference on two key areas of metallic materials: (i) mechanical behavior and properties evaluated by mechanical testing; and (ii) different types of metal working or forming operations to produce useful shapes. The book consists of 16 chapters which are divided into two parts. The first part contains nine chapters which describe tension (including elastic stress – strain relation, relevant theory of plasticity, and strengthening methods), compression, hardness, bending, torsion – pure shear, impact loading, creep and stress rupture, fatigue, and fracture. The second part is composed of seven chapters and covers fundamentals of mechanical working, forging, rolling, extrusion, drawing of flat strip, round bar, and tube, deep drawing, and high-energy rate forming. The book comprises an exhaustive description of mechanical properties evaluated by testing of metals and metal working in sufficient depth and with reasonably wide coverage. The book is written in an easy-to-understand manner and includes many solved problems. More than 150 numerical problems and many multiple choice questions as exercise along with their answers have also been provided. The mathematical analyses are well elaborated without skipping any intermediate steps. Slab method of analysis or free-body equilibrium approach is used for the analytical treatment of mechanical working processes. For hot working processes, different frictional conditions (sliding, sticking and mixed sticking–sliding) have been considered to estimate the deformation loads. In addition to the slab method of analysis, this book also contains slip-line field theory, its application to the static system, and the steady state motion, Further, this book includes upper-bound theorem, and upper-bound solutions for indentation, compression, extrusion and strip drawing. The book can be used to teach graduate and undergraduate courses offered to students of mechanical, aerospace, production, manufacturing and metallurgical engineering disciplines. The book can also be used for metallurgists and practicing engineers in industry and development courses in the metallurgy and metallic manufacturing industries.
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
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.
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.
Mechanical Working of Metals: Theory and Practice provides a comprehensive examination of the stress–strain relationships involved in the principal methods of shaping materials by mechanical working. This book discusses the various processing equipment and its application. Organized into seven chapters, this book begins with an overview of the metals utilized on a substantial scale for construction and engineering purposes. This text then examines the behavior of metal under compressive stress, which can be seen from an analysis of what happens when a cylindrical sample is compressed between two platens. Other chapters consider the effect of mechanical work on the structure and macro-properties of metals. This book discusses as well the classification of the processes used for mechanical working. The final chapter deals with the techniques of manufacturing tin cans, which are ideal packaging for food and beverages. This book is a valuable resource for mechanical engineers and metallurgists.
