Materials Processing Defects

447 Pages·1995·28.589 MB·English

by  S.K. Ghosh (Eds.)

STUDIES IN APPLIED MECHANICS 43
Materials Processing
Defects
STUDIES IN APPLIED MECHANICS
Methods of Functional Analysis for Application in Solid Mechanics (Mason)
.
10. Boundary Integral Equation Methods in Eigenvalue Problems of Elastodynamics and Thin
Plates (Kitahara)
11. Mechanics of Material Interfaces (Selvadurai and Voyiadjis, Editors)
12. Local Effects in the Analysis of Structures (Ladeveze, Editor)
13. Ordinary Differential Equations (Kurzweil)
14. Random Vibration- Status and Recent Developments. The Stephen Harry Crandall
Festschrift (Elishakoff and Lyon, Editors)
15. Computational Methods for Predicting Material Processing Defects (Predeleanu, Editor)
16. Developments in Engineering Mechanics (Selvadurai, Editor)
17. The Mechanics of Vibrations of Cylindrical Shells (MarkuP)
18. Theory of Plasticity and Limit Design of Plates (Sobotka)
19. Buckling of Structures-Theory and Experiment. The Josef Singer Anniversary Volume
(Elishakoff, Babcock, Arbocz and Libai, Editors)
20. Micromechanics of Granular Materials (Satake and Jenkins, Editors)
21. Plasticity. Theory and Engineering Applications (Kaliszky)
22. Stability in the Dynamics of Metal Cutting (Chiriacescu)
23. Stress Analysis by Boundary Element Methods (Bala~, SIcSdeka nd Sladek)
24. Advances in the Theory of Plates and Shells (Voyiadjis and Karamanlidis, Editors)
25. Convex Models of Uncertainty in Applied Mechanics (Ben-Haim and Elishakoff)
26. Strength of Structural Elements (Zyczkowski, Editor)
27. Mechanics (Skalmierski)
28. Foundations of Mechanics (Zorski, Editor)
29. Mechanics of Composite Materials- A Unified Micromechanical Approach (Aboudi)
30. Vibrations and Waves (Kaliski)
31. Advances in Micromechanics of Granular Materials (Shen, Satake, Mehrabadi, Chang and
Campbell, Editors)
32. New Advances in Computational Structural Mechanics (Ladeveze and Zienkiewicz, Editors)
33. Numerical Methods for Problems in Infinite Domains (Givoli)
34. Damage in Composite Materials (Voyiadjis, Editor)
35. Mechanics of Materials and Structures (Voyiadjis, Bank and Jacobs, Editors)
36. Advanced Theories of Hypoid Gears (Wang and Ghosh)
37A. Constitutive Equations for Engineering Materials
Volume 1: Elasticity and Modeling (Chen and Saleeb)
37B. Constitutive Equations for Engineering Materials
Volume 2: Plasticity and Modeling (Chen)
38. Problems of Technological Plasticity (Druyanov and Nepershin)
39. Probabilistic and Convex Modelling of Acoustically Excited Structures
(Elishakoff, Lin and Zhu)
40. Stability of Structures by Finite Element Methods (Waszczyszyn, Cicho~ and Radwahska)
41. Inelasticity and Micromechanics of Metal Matrix Composites (Voyiadjis and Ju, Editors)
42. Mechanics of Geomaterial Interfaces (Selvadurai and Boulon, Editors)
43. Materials Processing Defects (Ghosh and Predeleanu, Editors)
General Advisory Editor to this Series:
Professor Isaac Elishakoff, Center for Applied Stochastics Research, Department of Mechanical
Engineering, Florida Atlantic University, Boca Raton, FL, U.S.A.
STUDIES IN APPLIED MECHANICS 43
M a t e r i a l s P r o c e s s i n g
D e f e c t s
Edited by
S.K. Ghosh
GKN International College of Engineering
Lohmar, Germany
M. Predeleanu
LMT
University of Paris V/
Cachan, France
L~~
l
1995
ELSEVIER
Amsterdam- Lausanne- New York- Oxford- Shannon-Tokyo
ELSEVIER SCIENCE B.V.
Sara Burgerhartstraat 25
P.O. Box 211, 1000 AE Amsterdam, The Netherlands
pages 17-58 reprinted from Journal of Materials Processing Technology, Vol. 32, nos. 1-2 (1992)
ISBN 0-444-81706-9
(cid:14)91 995 Elsevier Science B.V. All rights reserved.
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Preface
The Second International Conference on Materials Processing Defects (Proceedings of
which was published as a special issue of the Journal of Materials Processing
Technology, Vol. 32, nos. 1-2, 1992, 530 pages) was held GKN Automotive AG
during 1 -3 July 1992. We believe that this technological field of defects, and more
appropriately, avoidance of them, is very current in perhaps all sectors of the
manufacturing industry. This is particularly important to reduce/minimize waste
everywhere to address lean production procedures.
The recent advances in finite plasticity and visioplasticity, damage modelling,
instability theories, fracture modelling, computer numerical techniques and process
simulation etc. offer new approaches and tools for defect prediction, analyses and
guidelines for designing components to be manufactured by traditional and emerging
process technologies.
The present volume includes contributions from well known researchers and experts in
this field, most of whom were also involved with the aforementioned Conference. The
main aim of the contributions has been to extend and generalize somewhat their past
contribution in the form a self-contained chapter on individual title topics such that a
volume would be possible. We do hope that it matches to a large extent with the stated
objectives considering the vast field of research into defects in all kinds of materials
processing and associated topics:
- Micro- and Macro-scale observation of defects
Localization and instability analysis
-
Damage modelling and fracture criteria
-
- F ormability characterization
- Defect prediction methods
- Design considerations to avoid defects
- Practical process/material considerations.
We are very indebted to the authors and referees of this volume for their generous and
very kind support. We would also thank Mrs. Heike Erlenkamp for all her help
towards this volume. Finally, the team at Elsevier, Amsterdam: Mrs. Mary McAdam,
Ms. Wilma van Wezenbeek, Dr. Bas van der Hoek and Dr. van der Hoop deserve
special thanks for their patience and care for professional preparation and presentation
of the book.
S K Ghosh M Predeleanu
Lohmar, Germany Paris, France
3 November 1994

vii
Dedicated to
Professor Frank W Travis DSc
Professor Vellore C Venkatesh DSc
on the occasion of their 60th birthdays
The proceedings of the Conference, based on which this present volume
has been initiated, was dedicated in 1992 to professor William Johnson
FRS FEng- This book on Materials processing Defects is dedicated
to my earlier teachers, professors Travis and Venkatesh. I do this with
great pleasure on behalf of all their students, research assistants, research
fellows, post doctoral researchers, colleagues and all others who have had
contact with them throughout their professional careers. It is very fitting
indeed that this dedication appears in a volume published by Elsevier since
both of them have been contributing through this publisher to the scientific
community of materials processing worldwide for many years.
My dedication to professors Travis and Venkatesh will be incomplete
without reference to their wives, Mrs. Jean Travis and Mrs. Gita
Venkatesh concerning their generous support, help and kind hospitality
always and everywhere, and especially, that extended to those, so-called
'foreign students/researchers abroad'.
It gives me great pleasure on all your behalf in wishing them continued
good health and happiness.
I~rofeee)or Swaclhin Kumar Ghoe)h
Dirsc~0r
GKN In~c~rnational College of: Engineering
Lohmar, Germany
This Page Intentionally Left Blank
CONTENTS
Preface
Dedication oo
VII
Some Comments on the Structure of Technology of Plasticity in
R&D and Production
K. Lange
James Nasmyth (1808-1890): The Steam Hammer and the Mechanics of
Vee-anvil Forging
W. Johnson 17
Modeling Dynamic Strain ~ization in Inelastic Solids
M. Predeleanu 59
Void Growth under Triaxial Stress State and its Influence on
Sheet Metal Forming Limits
R. C. Chaturvedi 75
The Prediction of Necking and Wrinkles in Deep Drawing Processes
Using the FEM
E. Doege, T. El-Dsoki and D. Seibert 91
Constitutive Models for Microvoid Nucleation, Growth and Coalescence
in Elastoplasticity, Finite Element Reference Modelling
J. Oudin, B. Bennani and P. Picart 107
Theoretical and Numerical Modelling of Isotropic or Anisotropic
Ductile Damage in Metal Forming Processes
J. C. Gelin 123
Research on Forging Processes for Production a + /3 Titanium
Alloy TCll Disks
Sencan Chen, Yu Xinlu, Zongshi Hu and Shaolin Wang 141
Modelling of Fracture Initiation in Metalforming Processes
Y.Y. Zhu, S. Cescotto and A.M. Habraken 155
Formability Determination for Production Control
J.A. Schey 171
Design of Experiments, a Statistical Method to Analyse Sheet Metal
Forming Defects Effectively
D. Bauer and R. Leidolf 187