Design and Development of Metal-Forming Processes and Products Aided by Finite Element Simulation

258 Pages·2017·13.63 MB·English

by  Ming Wang Fu (auth.)

Engineering Materials and Processes
Ming Wang Fu
Design and Development
of Metal-Forming
Processes and Products
Aided by Finite Element
Simulation
by Finite Element and
Soft Computing Methods
123
Engineering Materials and Processes
Series editor
Brian Derby, Manchester, UK
More information about this series at http://www.springer.com/series/4604
Ming Wang Fu
Design and Development
of Metal-Forming Processes
and Products Aided by Finite
Element Simulation
123
Ming WangFu
Department ofMechanical Engineering
TheHong Kong Polytechnic University
Hong Kong
China
ISSN 1619-0181 ISSN 2365-0761 (electronic)
Engineering MaterialsandProcesses
ISBN978-3-319-46462-6 ISBN978-3-319-46464-0 (eBook)
DOI 10.1007/978-3-319-46464-0
LibraryofCongressControlNumber:2016951705
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To my parents, my wife and partner, Yan Lei,
and my sons and daughter, Gabriel
Yongquan Fu, Grace Yongan Fu, and
Graham Yongji Fu.
Preface
In today’s rapidly changing product marketplace, the critical requirements for
product quality, productivity, and time-to-market have been becoming the most
powerful driving force behind any new product design and development
(PDD) paradigm for seeking the best design solution and quality product devel-
opment. This would render the design and development of products full of chal-
lenges.Fromdesignperspective,howtocomeoutwith“designrightthefirsttime”
and the best design solution is crucial for reducing “time-to-market” and ensuring
“quality and defect-free” product development. From product realization point of
view, it would reduce trial and error and shorten product development lead time.
In net-shape or near net-shape PDD, plastic deformation process is one of the
important manufacturing processes for fabrication of metal-deformed parts and
components. The parts or components produced by this traditional manufacturing
process are widely used in many industry clusters, ranging from computer, home
appliance, medical, consumer electronics, automobile to aerospace industries. The
high demand for shorter design and development lead times, good dimensional
accuracy, overall quality, and rapid design changes have become the bottleneck
issues in metal-forming industry. For the companies which want to maintain their
competitivenessandcuttingedgeinthisindustrialcluster,thereisanurgentneedto
shorten design and development lead times, reduce production cost, improve pro-
ductquality,andenhanceproductivity.Thesimulation-enabledPDDparadigmand
technologies in metal-forming arena help address the above-mentioned issues in
this traditional but now revitalizing and promising industrial cluster.
With the advent of finite element method (FEM), finite element (FE)-based
simulation, and their wide applications in plastic deformation processes, the
traditional metal-formed products development paradigm is shifted from the
heuristic know-how and trial and error to in-depth scientific calculation, analysis
andsimulationtosupportmetal-formedpartdesign,formingprocessdetermination
and configuration, product quality control and assurance, and the realization of
mass production of defect-free metal-formed products. The simulation-enabled
metal-formed PDD paradigm provides solutions to address these issues.
vii
viii Preface
In the past decades, extensive researches on simulation-enabled metal-formed
PDDhavebeenthoroughlyconductedinbothacademiaandindustry.Thedetailed
methodologies and techniques to support the above-mentioned design activities
have been well explored and developed. This book aims to report the
state-of-the-art advances in these areas, which include the fundamentals of
rigid-plastic FEM and the FEM-based simulation of metal-forming process,
simulation-aided metal-formed part design, process determination and configura-
tion, die design, and product quality assurance and control.
In this book, Chap. 1 first introduces the basis of plastic deformation of mate-
rials, plastic deformation or forming processes, and the forming system to realize
plastic deformation process. With the forming process and system, the
metal-formed parts are fabricated. In addition, the challenges of this traditional
manufacturing process are summarized and how to address these issues is briefly
summarized. In Chap. 2, the fundamental of rigid-plastic finite element method is
articulated, which is the kernel of FEM-based simulation in metal-forming pro-
cesses.The simulation of plastic deformation processes by FEM isthen elucidated
and the detailed case studies are given to show its applicability in metal-forming
arena.
InChap.3,howtheFEsimulationhelpsmetal-formedpartdesignisintroduced.
For a given designed product, there can be many design alternatives and solutions
generatedfrommetal-formedpartdesignperspective.Howgoodtheyareandhow
thecorrespondingformingsystemsperformareassessedbyusingFEsimulation.In
addition, the forming process determination and process parameter configuration
with the aid of FE simulation are presented. By using FE simulation, different
processroutesandprocessparameterconfigurations canbeevaluatedbased onthe
formability of materials under the given designed metal-forming parts and the
quality of the deformed parts. The focus of this chapter is on the evaluation of
metal-formed part design, process route, process parameter configuration, and the
designed metal-forming system by using FE simulation.
Inmetal-forming,dieisanimportanttooltodeformtheworkpieceinsuchaway
themetal-formedpartisfabricated.Dieworksunderaveryseverestresscondition
and the working stress is not uniformly distributed in the entire die structure and
thustheworkingstressneedstobecarefullyandrationallydesignedandcontrolled
to ensure the good performance and long service life. In Chap. 4, the
simulation-enabled die and forming system design is presented, which includes
different design approaches for die design aided by FE simulation and the
methodology to evaluate the entire forming system design based on the proposed
evaluation criteria.
In PDD, product quality, production cost, and time-to-market are three over-
riding issues. Product quality is the first and most important. In metal forming,
many defects can be generated in forming processes and some of them can be
classifiedintoflow-inducedandstress-induceddefects.Theformeriscausedbythe
irrationalflowpattern,whilethelatterisgeneratedbytheworkingstressexceeding
the strength limit of materials. The most common defect of the latter is the ductile
fracture occurring in forming process. In this book, how to identify these defects
Preface ix
and avoid them via FE simulation is presented in Chaps. 5 and 6. In Chap. 5,
the flow-induced defects in multiscaled plastic deformation processes are intro-
duced. The fundamental flow behaviors and formation mechanisms of defects in
different scales are revealed and how to avoid the defects is also articulated.
In Chap. 6, ductile fracture and stress-induced defects in multiscaled deformation
are described. The defect formation mechanisms and evaluation criteria are sum-
marized. The modeling, simulation, and prediction of the ductile fracture and
stress-based defects are summarized, which provide a systematic basis for defect
analysis in multiscaled, especially for microscaled plastic deformation.
Metal-forming hasbeenbecoming an importantmanufacturingprocessfor long
time due to its high productivity, good product quality, and low production cost.
Thisconventionalmanufacturingprocess,however,hasbeentraditionallylinkedto
long years of apprenticeship and skilled craftsmanship. The traditional product
design and development paradigm cannot meet more and more demanding
requirements in the current competitive marketplace, and the simulation-enabled
metal-formedPDD paradigmprovidessolutions toaddressthese issues.This book
is thus intended to give the comprehensive description and thorough articulation
of the state-of-the-art simulation-enabled PDD paradigm in this arena for students,
researchers, and engineers in industries, R&D organizations, and academia. In
addition, this book also provides valuable information to this manufacturing field
and can be used as a reference and textbook for a graduate course in learning this
very useful and practical manufacturing process.
Hong Kong, China Ming Wang Fu
Acknowledgements
I am indebted to the following institutions and individuals who have helped make
this book possible due to their generous supports and contributions to the research
activities from which the research outcomes and findings summarized in this book
arise.
(cid:129) The Hong Kong Polytechnic University (HK PolyU), Faculty of Engineering,
and the Department of Mechanical Engineering for providing various research
scholarships, grants, and resources which are pertinent to establishing the
research facilities and conducting the researches from which this book arises;
(cid:129) The General Research Fund and the Innovation and Technology Fund from
Hong Kong Government for funding the projects of B-Q08V, B-G33F
(515012), ITS/028/07, ITS/313/09, and ITS228/11 to the support of the
researches summarized in this book, and the project of No. 51575465 from the
National Natural Science Foundation of China;
(cid:129) DrW.L.Chan,Dr.H.Li,Dr.J.G.Liu,Dr.J.H.Deng,Dr.Q.Hu,Dr.Y.Q.Ning,
Dr.Y.Zhao,DrJ.Q.Ran,Dr.J.L.Wang,andDr.Z.T.Xufortheircontributions
to the projects acknowledged here or contributing part of their research results
when they worked under the above projects to this book.
Finally,Iwouldliketoexpressoursinceregratitudetomyfamilyforsupporting
me throughout conducting the researches and the publishing process. Their
understanding and support are critical and invaluable for the completion of the
above research projects and this book.
Ming Wang Fu
xi