METAL FORMING – PROCESS, TOOLS, DESIGN Edited by Mohsen Kazeminezhad Metal Forming – Process, Tools, Design http://dx.doi.org/10.5772/2850 Edited by Mohsen Kazeminezhad Contributors A. El Hami, B. Radi, A. Cherouat, Xin-Yun Wang, Jun-song Jin, Lei Deng, Qiu Zheng, M. Bakhshi-Jooybari, A. Gorji, M. Elyasi, Bernd Engel, Johannes Buhl, Tetsuhide Shimizu, Ming Yang, Ken-ichi Manabe, Marta Oliveira, Weizhong Guo, Feng Gao, Javier W. Signorelli, María de los Angeles Bertinetti Published by InTech Janeza Trdine 9, 51000 Rijeka, Croatia Copyright © 2012 InTech All chapters are Open Access distributed under the Creative Commons Attribution 3.0 license, which allows users to download, copy and build upon published articles even for commercial purposes, as long as the author and publisher are properly credited, which ensures maximum dissemination and a wider impact of our publications. 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Publishing Process Manager Oliver Kurelic Typesetting InTech Prepress, Novi Sad Cover InTech Design Team First published October, 2012 Printed in Croatia A free online edition of this book is available at www.intechopen.com Additional hard copies can be obtained from orders@intechopen.com Metal Forming – Process, Tools, Design, Edited by Mohsen Kazeminezhad p. cm. ISBN 978-953-51-0804-7 Contents Preface VII Section 1 Process 1 Chapter 1 Hydroforming Process: Identification of the Material’s Characteristics and Reliability Analysis 3 A. El Hami, B. Radi and A. Cherouat Chapter 2 Stamping-Forging Processing of Sheet Metal Parts 29 Xin-Yun Wang, Jun-song Jin, Lei Deng and Qiu Zheng Chapter 3 Developments in Sheet Hydroforming for Complex Industrial Parts 55 M. Bakhshi-Jooybari, A. Gorji and M. Elyasi Chapter 4 Forming of Sandwich Sheets Considering Changing Damping Properties 85 Bernd Engel and Johannes Buhl Section 2 Tools 109 Chapter 5 Impact of Surface Topography of Tools and Materials in Micro-Sheet Metal Forming 111 Tetsuhide Shimizu, Ming Yang and Ken-ichi Manabe Chapter 6 Towards Benign Metal-Forming: The Assessment of the Environmental Performance of Metal-Sheet Forming Processes 135 Marta Oliveira Section 3 Design 151 Chapter 7 The Design of a Programmable Metal Forming Press and Its Ram Motion 153 Weizhong Guo and Feng Gao Chapter 8 Self-Consistent Homogenization Methods for Predicting Forming Limits of Sheet Metal 175 Javier W. Signorelli and María de los Angeles Bertinetti Preface In this book, different aspects of metal forming are considered. Three important aspects are process, tools and design, which are sections names of the book. Each section consists of different chapters. In each chapter, the efforts are focused on presenting the state of art and also the new concepts and findings in process/tools/design. In describing the concepts, the emphasis is on the analysis and effect of materials characteristics. The first section, named “Process”, consists of three chapters on hydroforming and forging processes considering the analysis, production of complex parts and materials characteristics. Another chapter of this section is focused on the forming of sandwich sheets for controlling the damping properties. The second one, i.e. “Tools” section, consists of two chapters. The chapters are related to topography of tools and machine tools. The third one is related to design of a programmable metal forming press and methods for predicting forming limits of sheet metal. These designs can help the economical production of industries. Mohsen Kazeminezhad Sharif University of Technology, Iran Section 1 Process [...]... type of application 14 Metal Forming – Process, Tools, Design Figure 10 Experimental and numerical results of hydroforming using die cavity D1 Figure 11 Experimental and numerical results of hydroforming using die cavity D2 Hydroforming Process: Identification of the Material’s Characteristics and Reliability Analysis 15 Figure 12 Experimental and numerical results of hydroforming using die cavity... probabilistic 24 Metal Forming – Process, Tools, Design methodology allow to take account to the variability in metal forming process particularly is known that theses uncertainty have a significant impact on the success or the failure of the process and the quality of the final part Figure 19 Finite Element Model In general manner the RBDO is solved in two spaces physical space for the design variables... of the hydroforming process To obtain information from the output file of the ABAQUS/Explicit©, we use a developed Python code (see Figure 3) Figure 3 Identification process 4 Results and discussion A three dimensional finite element analysis (FEA) has been performed using the finite element code ABAQUS/Explicit to investigate the hydroforming processes 8 Metal Forming – Process, Tools, Design 4.1... internal pressure 5 6 16 Metal Forming – Process, Tools, Design Die cavity D1 D2 D3 Beginning instability (MPa) 4,90 2,85 5,10 Critical (MPa) 6,74 2,85 6,86 Experimental (MPa) 5,2 3,0 5,3 Table 3 Levels of pressure for different dies Figure 14 Optimisation of complex shape part 4.4 Optimization of sheet shape Optimization is the action of obtaining the preferable results during the part design In the CAE-based... medium, provided the original work is properly cited 4 Metal Forming – Process, Tools, Design experiences large plastic deformations, leading to the formation of high strain localization zones and, consequently, to the onset of micro-defects or cracks This damage initiation and its evolution cause the loss of the formed piece and indicate that the forming process itself should be modified to avoid the... INSA de Rouen, St Etienne de Rouvray, France B Radi LMMI, FST Settat, Settat, Morocco A Cherouat GAMMA3, UTT, Troyes, France 28 Metal Forming – Process, Tools, Design 7 References Asnafi, N & Skogsgardh, A (2000) Theoretical and experimental analysis of strokecontrolled tube hydroforming, Materials Science and Engineering A279, pp 95-110 Ayadi, A., Radi, B., Cherouat, A & El Hami A (2011) Optimization... hydroformed structure, International Journal Simulation of Multidisciplinary Design Optimization, 4, pp 39-47 Radi, B., El Hami, A & Cherouat, A (2012) Reliability Based Design Optimization Analysis of Tube Hydroforming Process, International Journal Simulation, in press Radi, B & El Hami, A (2007) Reliability analysis of the metal forming process, Mathematical and Computer Modelling, 45, pp 431-439 Sokolowski,... are the limits during hydroforming, how different material and process parameters influence the loading path and the forming result, and what an experimental investigation into hydroforming should focus on The hydroforming operation comprises two stages: free forming and calibration The portion of the deformation in which the tube expands without tool contact, is called free forming As soon as tool contact... state surface The m-dimensional uncertainty space in Ωs = X : G ( X ) > 0} thus divided into a safe region and a failure region Ωf = X : G ( X ) ≤ 0} (see Radi et al.,2007) ( { ) ( { ) 18 Metal Forming – Process, Tools, Design 5.1 Definition of the limit state functions The risk of failure is estimated based on the identification of the most critical element for necking and severe thinning For this reason... wrinkling tendency, this function is inspired from the FLD and given by the following expression:  N Fw =  d iw   i =1  εw = φ ( ε2 )   ( ) 2 N ( i =  ε1 − ε iw i =1 ) 2 (15) 20 Metal Forming – Process, Tools, Design where ε1 is the major strain in element i , and ε w is the wrinkling limit value determined from the FLD, N is the number of elements The success of a THP is dependent on a number . METAL FORMING – PROCESS, TOOLS, DESIGN Edited by Mohsen Kazeminezhad Metal Forming – Process, Tools, Design http://dx.doi.org/10.5772/2850. Metal Forming – Process, Tools, Design, Edited by Mohsen Kazeminezhad p. cm. ISBN 978-953-51-0804-7 Contents Preface VII Section 1 Process 1 Chapter 1 Hydroforming. fracture of the tube during the process. In fact, when a metallic material is formed by such processes, it Metal Forming – Process, Tools, Design 4 experiences large plastic deformations, leading