Metal Forming: Formability, Simulation, and Tool Design - Softcover

Nielsen, Chris V.; Martins, Paulo A.F.

Softcover

ISBN 10: 0323852556 ISBN 13: 9780323852555

Publisher: Academic Press, 2021

Synopsis

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

About this title

About the Authors

Chris Nielsen is Associate Professor at the Technical University of Denmark, research affiliate and recipient of the F.W. Taylor Medal Award by the International Academy for Production Engineering (CIRP), recipient of the International KARL-KOLLE Prize for metal forming by the German Metal Forming Association. He is the co-author of two books, two book chapters, and has authored 60 papers in international journals and conferences. His research focuses on metal forming, metal forming tribology, resistance welding, and resistance sintering. Most research involves a combination of experimentation and numerical modeling.

Paulo Martins is Professor of Manufacturing, at the Instituto Superior Técnico, University of Lisbon, Portugal. He is also Doctor Technices Honoris Causa of the Technical University of Denmark, and a Fellow of the International Academy for Production Engineering (CIRP). He is co‐author of six books, several international patents and over 350 papers in international journals and conferences. His main research area is manufacturing, specifically numerical and experimental-based development of forming and joining by forming processes.

From the Back Cover

Metal Forming is focused on formability, finite element simulation, and tool design. Providing both a bridge to research and a gateway to industry, it outlines essential knowledge on formability and finite element simulation for readers who want to learn about more advanced research topics, while also detailing the first steps in advanced industrial tool design and dimensioning.

The book starts with a chapter on formability covering fracture, plastic instability, and necking. This chapter also introduces the concepts of nucleation, growth, and coalescence of voids, and the characterization of the different crack opening modes in terms of plastic flow, microstructural damage, and fractography. Both coupled and uncoupled ductile damage criteria are considered.

The following three chapters are dedicated to finite element methods in metal forming, the first of which provides a user’s perspective on accuracy, reliability and validity of modelling, and answers questions such as which formulations are available for solving metal forming processes, what needs to be considered when selecting a specific formulation for solving a metal forming process, and how accurate and reliable are the estimates provided by finite element simulations. Refreshment of large deformation kinematics and solution techniques to solve non-linear systems of equations are also provided to help bridge the gap between developers and users of finite element computer programs. The second chapter on finite element methods focuses on flow formulation and is designed for readers who want to obtain a deeper understanding of how the finite element governing equations, iterative solution methods, friction and contact between objects, and many other topics can be integrated and merged in the development of an electro-thermo-mechanical finite element computer program for metal forming. The third chapter on finite element methods provides a brief introduction to the quasi-static solid formulation for elasto-viscoplasticity, based on an explicit time integration scheme to simplify the presentation and open the way for readers who want to progress to more sophisticated readings and implementations of the solid formulation.

The book concludes with a chapter on tool design covering design guidelines and technical information related to tool materials and lubricants. A MATLAB source code is provided for determining the deflections and stress distributions in the die core and stress rings of metal forming tools based on the use of pre-stressed containers.

About the Authors

Chris Nielsen is Associate Professor at the Technical University of Denmark, research affiliate, recipient of the F. W. Taylor Medal Award by the International Academy for Production Engineering (CIRP), and recipient of the International Karl-Kolle Prize for metal forming by the German Metal Forming Association.

Paulo Martins is Professor of Manufacturing at the Instituto Superior Técnico, University of Lisbon, Portugal. He is Doctor Technices Honoris Causa by the Technical University of Denmark and Fellow of the International Academy for Production Engineering (CIRP).

Edition details

• Publisher: Academic Press
• Publication date: 2021
• Language: English
• ISBN 10: 0323852556
• ISBN 13: 9780323852555
• Binding: Paperback
• Edition number: 1
• Number of pages: 428