Analysis and technology in metal forming 29 influence of strainrate i. For each primary class of processes, such as forging, rolling, extrusion, wiredrawing, and sheet metal forming, it explains how fea finite elements analysis can be applied with great precision to characterize the forming condition and in this way optimize the processes. The deep drawing process is applied with the intention of manufacturing a product with a. Mechanical engineering approved by the examining committee. Although many new flexible forming processes have been invented, they have largely not had industrial application, so it would be valuable if intelligent means to design new processes existed. His work covers all main metal forming processes, including forging, rolling, extrusion, drawing, and sheet metal forming. Professor valbergs main fields of research are materials, metal forming, experimental deformation analysis, and fe analysis.
In recent years, enormous progress has been made in the analysis of forming of complex shapes using. The application of computeraided design and manufacturing techniques is becoming essential in modern metal forming technology. 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. Table 1 gives an overview of the reality and of simulation models in use today. Finite element analysis fea has been developed during the last decades as a very useful tool for analysis of metal forming processes. Use features like bookmarks, note taking and highlighting while reading applied metal forming. Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. There is, however, a wide gulf between the statement of the basic laws governing deformation in sheet metal and the application of. A time dependent elasticviscoplastic model has been used to represent the flow type behavior of metals at. Application of the finite element method in metal forming. Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section. The application of the finite element method fem for the simulation of metal forming processes has provided a rational methodology for designing and optimizing these processes.
Using fem analysis describes metal forming theory and how experimental techniques can be used to study any metal f. This is a pdf file of an unedited manuscript that has been accepted for. Feasibility studies, process streamlining and predicting. Metal forming, third edition this book is designed to help the engineer understand the principles of metal forming and analyze forming problems both the mechanics of forming processes and how the properties of metals interact with the processes. Including fem analysis describes metal forming theory and how experimental techniques can be used to study any metal forming operation with great accuracy. Metal forming analysis the introduction of numerical methods, particularly. For each primary class of processes, such as forging, rolling, extrusion, wiredrawing, and sheet metal forming, it explains how.
A new approach based on the nodebased smoothed finite element method ns fem edgebased smoothed finite element method es fem is presented for the analysis of contactimpact problems with large deformations and for the simulation of metal forming processes. Finite element analysis of an aluminium alloy sheet in a v. In this paper, the finite element method has been utilized for a consistent analysis of coupled thermo mechanical large deformation of metals. In light of these developments, the finite element methoda technique by which an object is decomposed into pieces and treated as isolated, interacting. Metal forming is the main method of making metal products and semifinished products. Shape is a reliable fe based solution provider, which covers a wide range of roll forming and rotary forming simulations including ring rolling, tube spinning. Application of finite element analysis in multiscale metal forming. Plastic properties of metals are used during the process of metal forming. Finite element analysis of sheet metal forming process 62 figure 5. The first scale is the global modeling, which only predicts process loads or work. Abstractsimulation of sheet metal forming processes involves large deformation analysis. When we compare the physical reality of a sheet metal forming process with the simulation models used today, we recognize that significant factors in the forming process are incorrectly described in the simulation model, or even not at all 5. Indeed, the method has become an integral part of computeraided engineering 141, however, while there is a wide use of the finite element method, the simulation of forming processes still provides a great challenge because of the.
It also provides powerful analysis tools for heat transfer, roll stress and microstructure analyses. Mechanics of sheet metal forming college of engineering. More than 90% of smelted metal is processed by different methods of metal forming. In past researchers had worked on the area of finite element analysis of stretch flanging process in terms of development of fem based computer programs and by using different commercial fem software packages.
Thus, using fea it is now possible to visualize any metal forming process and to study strain, stresses, and other forming conditions inside the. Based on the principle of layered manufacture in rapid prototype technology, this process resolves the intricate threedimensional geometry information of the workpiece into a series of twodimensional data, which can be used by an nc. The introduction of numerical methods, particularly finite element fe analysis, represents a significant advance in metal forming operations. Thus process modeling for the determination of deformation mechanics has been a major concern in research. It is used for making of automotive components and complex panels. Nsfemesfem for contact problems in metal forming analysis. A finiteelement analysis of sheet metal forming processes.
The rigid plastic finite element method fem, which was developed by lee and. Including fem analysis describes metal forming theory and how experimental techniques can be used to study any metal forming. In metal forming processes, friction between tool and workpiece is an. The modified fe model in microforming has been applied with the consideration of size effects including material characterization, frictioncontact characterization. For each primary class of processes, such as forging, rolling, extrusion, wiredrawing, and sheetmetal forming, it explains how. On the state of finite element procedures for forming processes. Using the finite element method in metalforming processes. Finite element analysis of sheet metal forming process. For each main process, such as forging, rolling, extrusion, wiredrawing, and sheetmetal forming, it demonstrates how fea finite elements analysis can. Using fem analysis describes metal forming theory and how experimental techniques can be used to study any metal forming operation with great accuracy.
It provides the 3d coordinates of the components surface as well as the distribution of major and minor strain on the surface and the. Forging process analysis and preform design by harshil parikh, bhavin mehta, jay gunasekera department of mechanical engineering ohio university, athens, ohio 45701 rob mayer, president queen city forging company, cincinnati, ohio 45226 abstract the purpose of this paper is to optimize the forging process and reduce the required force. Since then, the finiteelement method has assumed steadily increased importance in simulation of metal forming processes. An analysis of metal forming processes using large deformation elastic plastic formulations jungho cheng and noboru kikuchi department of mechanical engineering and applied mechanics, the university of michigan, ann arbor, mi 48109. Numerical methods are used increasingly to optimize product design and deal with problems in metal forging, rolling, and extrusion processes.
The technique of sheet metal forming analysis requires a noncontact optical 3d deformation measuring system. Surfaces that hold the blank before the forming operation, including the restraining. Metal forming processes full notes ebook free download pdf. The model has been optimized to experimental results with respect to strains at the edge of the sheet and spring back of the sides of the profile. Most sheet metal components are made by deep drawing, which requires expensive tooling.
Zhang school of mechanical engineering, jiangsu university, zhenjiang, 2120, pr china. Review of friction modeling in metal forming processes dtu orbit. Controlled fem simulation ways of blank holding force in. Among the books cited, however, only a few discuss the application of the finiteelement method to metal forming processes. He was a visiting professor at denmarks technical university in 199798. The hot stamping process of highstrength steel sheet is complicated and the forming quality of sheet metal is affected by many factors, so it is necessary to simulate the hot forming process with finite element method and grasp the influence of process parameters on forming quality. Including fem analysis describes metal forming theory and how experimental techniques can be used to study metal forming operations with great accuracy. This page intentionally left blank applied metal forming including fem analysis applied metal forming.
Fraunhofer iwu applies the finiteelement method for designing forming and cutting processes as well as qualifying. Elsevier journal of materials processing technology 54 1995 7075 joura of materials processing technology a finite element analysis of sheet metal forming processes tzechi hsu, chanhung chu department of mechanical engineering, yuanhe institute of technology, far east rd. Automated modeling and remeshing in metal forming simulation by nitin vasant hattangady a thesis submitted to the graduate faculty of rensselaer polytechnic institute in partial fulfillment of the requirements for the degree of doctor of philosophy major subject. Simulation of sheet metal forming necessary developments in. Simon hellborg a finite element model has been developed to simulate the forming of a channel section profile with the roll forming method. Introduction metal forming process analysis and technology in metal forming plasticity and viscoplasticity methods of analysis the finite element method 1 the finite element method 2 plane. Metal forming, finite element analysis, simulations.
The system analyzes, calculates and documents deformations of sheet metal parts, for example. The analysis of deformation in sheet metal forming is often based on the two. Computer simulation has become reliable and acceptable in the metal forming industry since the 1980s. Metal forming analysis can be performed in three modeling scales 2. Download it once and read it on your kindle device, pc, phones or tablets. Groover, fundamentals of modern manufacturing 2e material behavior in metal forming plastic region of stressstrain curve is primary interest. Controlled fem simulation ways of blank holding force in sheet metal forming process l. This paper introduced the fundamentals of the sheet incremental forming process.