Metal Forming Processes: Developments in Experimental and Numerical Approaches

Cover
Half Title
Title Page
Copyright Page
Table of Contents
Preface
Contributors
Notes on the Editors
Chapter 1: Artificial Neural Network (ANN) Based Formability Prediction Model for 22MnB5 Steel under Hot Stamping Conditions
1.1 Introduction
1.2 Experiment
1.2.1 Material Used
1.2.2 Thermo-Mechanical Test (Gleeble-3800 Test)
1.3 Results and Discussion
1.3.1 Tensile Test
1.3.2 Forming Limit Diagram
1.4 ANN Model
1.5 Conclusion
References
Chapter 2: Shock Tube Based Forming of Sheets
2.1 Introduction
2.2 Static and Dynamic Behavior of Sheet Metal
2.3 Dynamic Sheet Forming Device
2.3.1 Drop Hammer Rig
2.3.2 Modified Split Hopkinson Pressure Bar
2.3.2.1 Working Principle
2.3.2.2 Advantages
2.3.2.3 Limitations
2.4 High Energy Rate Forming Processes
2.4.1 Electromagnetic Forming
2.4.1.1 Working Principle
2.4.1.2 Process Parameters and Their Influences
2.4.1.3 Advantages
2.4.1.4 Limitations
2.4.1.5 Applications
2.4.2 Electrohydraulic Forming
2.4.2.1 Working Principle
2.4.2.2 Process Parameters and Their Influences
2.4.2.3 Advantages
2.4.2.4 Limitations
2.4.2.5 Applications
2.4.3 Explosive Forming
2.4.3.1 Working Principle
2.4.3.2 Process Parameters and Their Influences
2.4.4 Shock Tube Based Forming
2.4.4.1 Working Principle
2.4.4.2 Process Parameters and Their Influences
2.4.4.3 Advantages
2.4.4.4 Limitations
2.4.4.5 Applications
2.4.4.6 Forming Behavior and Failure Response Analysis using a Shock Tube
References
Chapter 3: Bending of Sheet Metals: Challenges and Recent Developments
3.1 Introduction
3.2 Theory of Bending
3.3 Various Bending Processes
3.4 Measurement of Bendability
3.4.1 Pure Bend Test
3.4.2 V-Bend Test
3.4.3 Tight Radius Bend Test
3.5 Effect of Mechanical Properties on Bendability
3.6 Effect of Microstructure on Bendability
3.6.1 Effect of Grain Size, Shape and Boundaries on the Bendability
3.6.2 Effect of Residual Stress on Bendability
3.6.3 Effect of Crystallographic Texture on Bendability
3.6.4 Effect of Precipitates/Second Phase Particles
3.7 Defects or Instabilities During Bending
3.7.1 Kinking
3.7.2 Springback
3.8 Recent Developments
3.8.1 Bending of Magnesium Sheet
3.8.2 Microbending
3.8.3 Electromagnetic Bending
3.9 Conclusions
References
Chapter 4: Friction Stir Welding (FSW) and Friction Stir Spot Welding of Dissimilar Sheet Materials
4.1 Introduction
4.2 Dissimilar Joining of Aluminium and Steel Grades
4.3 Joining of Aluminium Alloy to Copper Alloy
4.4 FSW of Aluminium and Polymer
4.5 Joining of Aluminium to Titanium Alloy
4.6 Tool Wear
References
Chapter 5: Cryorolling of Aluminum Alloy Sheets and Their Characterization: A Review
5.1 Introduction
5.2 Cryorolling
5.3 Microstructural Evolution during Cryorolling
5.4 Effect of Cryorolling on Mechanical Properties
5.4.1 Tensile Properties
5.5 Effect of Heat Treatment and Post Processing on Cryorolled Sheets
5.6 Formability of Cryorolled Sheets and Evaluation
5.6.1 Improvement in Formability of Cryorolled Sheets
5.6.1.1 Warm Forming
5.6.1.2 Hydroforming
5.6.2 Micro Forming of Ultrafine-Grained Sheets
5.7 Summary
References
Chapter 6: Deformation Mechanism in Single Point Incremental Forming (SPIF) and Significance of Crystallographic Texture in Sheet Metal Forming Operations
6.1 Introduction
6.2 Forming Behavior and Deformation Mechanism in SPIF
6.3 Significance of Microstructure and Crystallographic Texture in Sheet Metal Forming
6.3.1 Quantitative Description of Texture
6.3.1.1 Texture Components in Face-Centered Cubic (FCC) Metals
6.3.1.2 Orientation Fiber
6.3.2 Deformation Mechanism and Forming Behavior in SPIF as per Developed Textures
6.3.2.1 Undeformed Sheet Material
6.3.2.2 Early SPIF Stage
6.3.2.3 Intermediate and Final SPIF Stage
6.4 Finite Element Analysis
6.5 Conclusion
References
Chapter 7: Tribological Behavior in Bulk and Sheet Forming Processes
7.1 Introduction
7.2 Metal Forming
7.2.1 Rolling
7.2.1.1 Wear During Rolling Process
7.2.2 Forging
7.2.2.1 Hot Forging
7.2.2.2 Cold Forging
7.2.2.3 Lubricants for Forging Processes
7.2.3 Extrusion and Drawing
7.2.3.1 Extrusion
7.2.3.2 Lubrication in Extrusion Processes
7.2.3.3 Drawing
7.2.3.4 Wear of Drawing Dies
7.2.4 Tribology in Sheet Metal Forming
7.2.4.1 Tribological Systems
7.2.4.2 The Stribeck Curve in Sheet Metal Forming
7.2.4.3 Lubrication Influence in Sheet Metal Forming
7.2.5 Powder Forging Process
7.2.5.1 Lubrication of Powder Producing Dies
7.3 Conclusion
References
Chapter 8: Hole Expansion Ratio (HER) for Automotive Steels
8.1 Introduction
8.2 Difference Between Hole Expansion and Uniaxial Tensile Deformation
8.3 Affecting Factors of HER
8.3.1 Microstructure
8.3.2 Mechanical Properties
8.3.3 Hole Preparation Method
8.3.4 Punch Geometry
8.4 Conclusions
References
Chapter 9: Forming and Fracture Limit Diagrams of Inconel 718 Alloy at Elevated Temperatures
9.1 Introduction
9.2 Materials and Methods
9.2.1 Material
9.2.2 Nakazima Test
9.3 Results and Discussion
9.3.1 Forming Limit Diagram
9.3.1.1 Strain Distribution
9.3.1.2 Bending Correction on Forming Limit Diagram (FLD)
9.3.1.3 Thickness Distribution
9.3.1.4 Limit Dome Height (LDH)
9.3.2 Fracture Forming Limit Diagram
9.4 Conclusion
Acknowledgement
References
Chapter 10: Tensile Properties and Anisotropy of Cross-Rolled Sheets: An Overview
10.1 Introduction
10.2 Cross Rolling
10.3 Methods for Measuring Formability of Sheets
10.4 Tensile Properties and Anisotropy of Cross-rolled Sheets
10.4.1 Body Centered Cubic (BCC) Materials
10.4.2 Face Centered Cubic (FCC) Materials
10.4.3 Hexagonal Closed Pack (HCP) Materials
10.4.4 Dual Phase Materials
10.4.5 Bio-Compatible Alloys
10.4.6 Cryogenic Cross-Rolled Sheets
10.5 Summary
10.6 Concluding Remarks
References
Chapter 11: A Review on Process Limitations and Recent Advancements in Single Point Incremental Sheet Forming
11.1 Introduction
11.1.1 Background
11.1.2 Benefits of Single Point Incremental Forming (SPIF)
11.1.3 Applications and Limitations of SPIF
11.1.4 Major Limitations in SPIF
11.1.4.1 Forming Load in SPIF
11.1.4.2 Forming Limits in SPIF
11.1.4.3 Thickness Distribution in SPIF
11.1.4.4 Geometrical Accuracy in SPIF
11.1.4.5 Surface Quality in SPIF
11.1.5 Recent Advancements in SPIF
11.2 Conclusion
References
Chapter 12: Single-Stage to Multi-Stage Incremental Sheet Forming Technology: State of the Art
12.1 Introduction
12.2 Multi-stage Incremental Sheet Forming
12.2.1 Toolpath and Forming Strategies in Multi-Stage Incremental Sheet Forming (MSPIF)
12.3 Parametric Investigation of Multi-Stage Incremental Sheet Forming
12.3.1 Friction and Forming Tool Direction
12.3.2 Lubricant in ISF Process
12.3.3 Angle Interval (Da) Between Stages
12.4 Case Study-MSPIF
12.5 Conclusion
References
Chapter 13: Multi-Response Optimization of Process Parameters to Minimize Geometric Inaccuracies in the Single Point Incremental Forming Process
13.1 Introduction
13.1.1 Geometric Accuracy
13.2 Experimental Details
13.2.1 Process Variables of Single Point Incremental Forming Process (SPIF)
13.2.2 Utility Concept
13.3 Results and Discussions
13.3.1 Preference Scale
13.3.2 Utility Value Calculation
13.3.3 Analysis S/N Ratio of Utility
13.3.4 Estimation of Mean for Utility
13.3.5 Confirmation Experiment
13.4 Summary
References
Chapter 14: A Review on Formability of Tailored Sheets in Incremental Forming
14.1 Introduction
14.2 Tailor Welded Sheet
14.3 Tailor Bimetallic Sheet
14.4 Tailor Laminated Blank
14.5 Future Scopes
References
Index