Analysis and Optimization of Sheet Metal Forming Processes

✍ Scribed by Amrut Mulay (editor), Swadesh Kumar Singh (editor), Andrzej Kocanda (editor)

• Publisher: CRC Press
• Year: 2024
• Tongue: English
• Leaves: 371
• Edition: 1
• Category: Library

✦ Synopsis

Analysis and Optimization of Sheet Metal Forming Processes comprehensively covers sheet metal forming, from choosing materials, tools and the forming method to optimising the entire process through finite element analysis and computer-aided engineering.

Beginning with an introduction to sheet metal forming, the book provides a guide to the various techniques used within the industry. It provides a discussion of sheet metal properties relevant to forming processes, such as ductility, formability, and strength, and analyses how materials should be selected with factors including material properties, cost, and availability. Forming processes including shearing, bending, deep drawing, and stamping are also discussed, along with tools such as dies, punches, and moulds. Simulation and modelling are key to optimising the sheet metal forming process, including finite element analysis and computer-aided engineering. Other topics included are quality control, design, industry applications, and future trends.

The book will be of interest to students and professionals working in the field of sheet metal and metal forming, materials science, mechanical engineering, and metallurgy.

✦ Table of Contents

Cover
Half Title
Title
Copyright
Dedication
Contents
Foreword
Foreword
Preface
Acknowledgements
Editors
Contributors
Chapter 1 Roll Forming in Sheet Metal Forming: Principles and Processes
1.1 Introduction
1.2 Deformation Modes in Roll Forming
1.2.1 Origin of Redundant Deformation
1.3 Analysis of the Roll Forming Process
1.3.1 Deformation Length and Bend Angle
1.3.2 Effects of Geometric Variables
1.3.3 Determination of Roll-Forming Loads
1.4 Defects in Roll Forming
1.4.1 Longitudinal Bow and Twist
1.4.2 Edge Wave
1.4.3 Center Wave and Corner Buckling
1.4.4 Edge Cracking and Splitting
1.4.5 Springback
1.4.6 End Flares
1.4.7 Effects of Residual Stresses on Roll-Formed Product Quality
1.5 Recent Developments in Roll Forming
1.5.1 Flexible Roll Forming
1.5.2 Microroll Forming
1.5.3 Branching in Roll Forming
1.6 Summary and Conclusions
Chapter 2 A Systematic Review of the Rotary Piercing Process
2.1 Introduction
2.2 Theoretical and Finite Element Method Studies of the Rotary Piercing Process
2.3 Experimental Studies of Rotary Piercing
2.4 Comparative Studies of Rotary Piercing with Experimental Methods and FEM
2.5 Summary of the Rotary Piercing Process
2.6 Conclusion
Chapter 3 Finite Element Analysis of the Metal Spinning Process
3.1 Introduction
3.2 Principles and Procedures of Metal Spinning
3.3 Spinning Processes
3.3.1 Conventional or Traditional Spinning
3.3.2 Shear Spinning
3.3.3 Flexible or Mandrel-Free Spinning
3.3.4 Hot Spinning
3.4 Spinning Process Parameters
3.4.1 Feed Ratio
3.4.2 Roller Path
3.4.3 Roller Design
3.4.4 Spinning Ratio (β)
3.5 Advantages and Limitations of Spinning
3.5.1 Advantages
3.5.2 Limitations
3.6 Finite Element Simulation of Spinning
3.7 Experimental Validation of the Model
3.7.1 Spinning of Cylindrical Component Using Circular Blank
3.8 Applications and Future Scope
3.9 Summary
Chapter 4 High-Energy Rate Forming
4.1 Introduction
4.2 Electromagnetic Forming/Magnetic Pulse Forming
4.2.1 Design Consideration for Coils
4.2.2 Design Consideration for Dies
4.2.3 Process Parameters
4.2.4 EMF Materials
4.2.5 Advantages of EMF
4.2.6 Disadvantages of EMF
4.3 Electro-Hydraulic Forming
4.3.1 Processes and Equipment Used in Ehf
4.3.2 Types of Discharges Used in Ehf
4.3.3 Design Consideration for Dies
4.3.4 Ehf Process Parameters
4.3.5 Ehf Applications
4.3.6 Advantages of Ehf
4.3.7 Disadvantages of Ehf
4.4 Explosive Forming
4.4.1 Description of Process
4.4.2 Types of Explosives
4.4.3 Explosive Forming Techniques
4.4.4 Explosive Forming Process Parameters
4.4.5 Explosive Forming
4.4.6 Advantages of Explosive Forming
4.4.7 Disadvantages of Explosive Forming
Chapter 5 The Formability of Aluminium and Its Alloy Sheet Metals: A Review
5.1 Introduction
5.2 Forming Limit Diagram
5.3 Necking Failure
5.4 Drawability
5.5 Wrinkling
5.6 Forming, Fracture and Wrinkling Limit
5.7 Effects of Annealing Temperature on Void Properties
5.8 Effects of Cryo-Rolling on Formability
5.9 Conclusions
5.10 Acknowledgments
Chapter 6 Analysis of Deep Drawing Quality Steel Using Incremental Hole Flanging with Different Pre-Cut Hole Diameters
6.1 Introduction
6.2 Materials and Methods
6.2.1 Mechanical Characterization
6.2.2 Multistage IHF Trials
6.2.3 Finite Element Analysis
6.2.4 Microtexture and Ra
6.2.5 Arithmetical Studies of Ductile Fracture
6.3 Results and Discussion
6.3.1 Limiting Forming Ratio
6.3.2 Formability Limit
6.3.3 Evaluation and Comparison of Various Theoretical Models Utilized to Forecast Fracture Loci
6.3.4 Strain Path Evolution
6.3.5 The Profile of the Vertical Force during IHF
6.3.6 Distribution of the Wall Thickness
6.3.7 Characterization of Micro-Texture
6.3.8 Surface Roughness
6.4 Conclusions
6.5 Conflict of Interest
Chapter 7 Applications of Incremental Sheet Forming
7.1 Introduction
7.2 Incremental Sheet Forming Types
7.3 Emerging Incremental Sheet Forming Methods
7.4 Machine Learning in Incremental Sheet Forming
7.5 Applications of Incremental Sheet Forming
7.6 Conclusions
Chapter 8 Finite Element Analysis of the Incremental Forming Process
8.1 Introduction
8.2 Incremental Forming
8.3 Finite Element Analysis
8.4 Results and Discussion
8.5 Conclusions
Chapter 9 The Incremental Sheet Forming of Light Alloys
9.1 Introduction
9.2 Principles and Procedures of ISF
9.3 ISF Parameters
9.3.1 Feed Rate
9.3.2 Spindle Speed
9.3.3 Pitch Size
9.3.4 Tool Geometry
9.3.5 Sheet Thickness
9.3.6 Lubricant
9.3.7 Forming Temperature
9.3.8 Tool Path
9.4 Advantages and Limitations of ISF
9.4.1 Advantages
9.4.2 Limitations
9.5 ISF of Light Alloys
9.6 ISF Applications in Industry
9.7 Future Scope and Commercialization
9.8 Summary
Chapter 10 Formability and Surface Integrity in Incremental Sheet Metal Forming
10.1 Introduction
10.2 Hot Incremental Forming
10.3 High-Speed Incremental Forming
10.4 Lubricants in Incremental Forming
10.5 Coating in Incremental Forming
10.6 Conclusions
10.7 Acknowledgement
Chapter 11 Optimizing Process Parameters in Novel SPIF to Reduce Excessive Thinning and Geometrical Inaccuracies for Aluminum Alloys
11.1 Introduction
11.2 Influence of the Process Parameters
11.2.1 Influence of Step Depth
11.2.2 Influence of Feed Rate
11.2.3 Influence of Spindle Speed
11.2.4 Influence of Tool Diameter and Tool Profile
11.3 Investigating the Effects of ISF Process Parameters on Sheet Thickness Reduction and Geometric Accuracy—A Case Study
11.3.1 Design of Experiments
11.3.2 Simulation Process
11.3.3 Results and Discussion
11.3.4 Influences on Sheet Thickness Reduction
11.3.5 Influences on Geometric Accuracy
11.4 Conclusion
Chapter 12 The Impacts of Generatrix Radius Variation and Temperature on Spifability in Warm Incremental Forming: A Comprehensive Study
12.1 Introduction
12.2 Role of Different Forming Parameters in ISF
12.2.1 The Role of Step Depth in Incremental Forming
12.2.2 The Role of Feed Rate in Incremental Forming
12.2.3 The Role of Spindle Speed in Incremental Forming
12.2.4 The Role of Tool Shape and Size in Incremental Forming
12.2.5 The Role of Sheet Thickness in Incremental Forming
12.2.6 The Role of Lubricant in Incremental Forming
12.2.7 The Effects of Generatrix in Incremental Forming
12.3 Material and Methodology
12.4 Results and Discussions
12.4.1 Temperature and Spifability
12.4.2 Generatrix Radius of Curvature and Spifability
12.5 Conclusions
12.6 Acknowledgement
Chapter 13 Numeric Investigations to Improve the Final Sheet Thickness in the SPIF of DC04 Sheets
13.1 Introduction
13.2 Methodology
13.3 Results and Discussion
13.3.1 The Effects of the Tool Path on the Sheet Thickness
13.3.2 The Effects of the Tool Profile on the Sheet Thickness
13.3.3 The Effects of Tool Step-Over (%) on the Sheet Thickness
13.4 Response Surface 3D Graphs for Minimum Sheet Thickness
13.5 Conclusion
13.6 Acknowledgement
Chapter 14 Hydroforming: State-of-the-Art Developments and Future Trends
14.1 Introduction to Hydroforming
14.2 The Future of Hydroforming
14.3 Tube Hydroforming
14.3.1 Process Description
14.3.2 Materials Used in THF
14.3.3 Applications
14.4 Sheet Metal Hydroforming
14.4.1 New Approaches to SHF
14.4.2 Applications
14.5 Computer Simulations in Hydroforming
14.5.1 Finite Difference Method
14.5.2 Finite Element Simulation
14.5.3 Meshfree Method
14.6 Conclusion
Chapter 15 Applying Adaptive and Arlequin Meshing to Tensile Testing and Metal Forming
15.1 Introduction
15.2 Material and Methods
15.3 Methodologies and Process Plan
15.3.1 Standard Method
15.3.2 Adaptive Meshing
15.3.3 Hierarchical Adaptivity
15.3.4 Polynomial Adaptivity
15.3.5 Relocation Adaptivity
15.3.6 Arlequin Method
15.4 Nonlinear FE Analysis
15.4.1 Newton–Rapson Method
15.5 Results and Discussion
15.5.1 Tensile Testing
15.6 Deep Drawing
15.7 Stretch Forming
15.8 V Bending
15.9 Conclusions
Chapter 16 Edge Formability in Sheet Metal Forming
16.1 Introduction
16.2 Flanging
16.3 Edge Formability
16.4 Edge Formability Test
16.5 Parameters That Influence Edge Formability
16.5.1 Microstructure
16.5.2 Mechanical Properties
16.5.3 Hole Preparation
16.5.4 Hole Diameter
16.5.5 Burr Position
16.5.6 Punch Geometry
16.6 Conclusion
Chapter 17 Finite Element Analysis of AA6061/AA5754 Bimetallic Sheets by Constrained Groove Pressing
17.1 Introduction
17.2 Constrained Groove Pressing
17.3 Finite Element Analysis
17.4 Results and Discussion
17.5 Conclusions
Chapter 18 Fracture Formation Limits in Sheet Metal Forming
18.1 Introduction
18.2 Theoretical Aspect
18.2.1 Fracture Forming Limit Line
18.3 Experimental Method and Procedure
18.3.1 Determination of FFL
18.4 Results
18.5 Conclusion
Chapter 19 The Role of Lubrication in Sheet Metal Forming Processes
19.1 Introduction
19.2 Types of Lubrication
19.2.1 Dry Condition
19.2.2 Boundary
19.2.3 Mixed Film
19.2.4 Hydrodynamic
19.3 Friction Laws
19.4 Lubricants in Sheet Metal Forming
19.4.1 Classification of Lubricants
19.4.2 Methods of Lubricant Application
19.4.3 Additives in Lubricants
19.4.4 Corrosion Control in Sheet Metal Stamping
19.4.5 Cleaning Procedures in Sheet Metal Stamping
19.4.6 Pre-Lubricants in Contemporary Stamping Processes
19.4.7 Post-Metal-Forming Operations in Sheet Metal Processing
19.5 The Tribological Assessment of Lubricants in Sheet Metal Forming
19.5.1 Laboratory-Scale Tests
19.5.2 Deep Drawing and Ironing
19.5.3 Warm and Hot Stamping
19.5.4 Punching and Blanking
19.6 Summary
Index