By an engineer with decades of practical manufacturing experience, this book is a complete modern guide to sheet metal forming processes and die design - still the most commonly used methodology for the mass-production manufacture of aircraft, automobiles, and complex high-precision parts. It illustrates several different approaches to this intricate field by taking the reader through the "hows" and "whys" of product analysis, as well as the techniques for blanking, punching, bending, deep drawing, stretching, material economy, strip design, movement of metal during stamping, and tooling. While concentrating on simple, applicable engineering methods rather than complex numerical techniques, this practical reference makes it easier for readers to understand the subject by using numerous illustrations, tables, and charts. Emphasizes the influence of materials as an aid to understanding manufacturing processes and operations. Features the essential mathematical formulas and calculations needed for various die operations and performance evaluation. Shows the comparative advantages and liabilities for each manufacturing process and operation. Offers a complete picture of the knowledge and skills needed for the effective design of dies for sheet-metal forming processes highlighted with illustrative examples. Provides properties and typical applications of selected tool and die materials for various die parts.

This book helps the engineer understand the principles of metal forming and analyze forming problems - both the mechanics of forming processes and how the properties of metals interact with the processes. In this fourth edition, an entire chapter has been devoted to forming limit diagrams and various aspects of stamping and another on other sheet forming operations. Sheet testing is covered in a separate chapter. Coverage of sheet metal properties has been expanded. Interesting end-of-chapter notes have been added throughout, as well as references. More than 200 end-of-chapter problems are also included.

This book contains useful instruction and information for metal workers, from novice to intermediate and even advanced, on how to apply force and use good judgment, thorough planning, close observation, creativity, and restraint to create almost any metal part. With this book, simple to complex fabrication and metal forming tasks are within the reach of adept enthusiasts.

This comprehensive book offers a clear account of the theory and applications of advanced metal forming. It provides a detailed discussion of specific forming processes, such as deep drawing, rolling, bending extrusion and stamping. The author highlights recent developments of metal forming technologies and explains sound, new and powerful expert system techniques for solving advanced engineering problems in metal forming. In addition, the basics of expert systems, their importance and applications to metal forming processes, computer-aided analysis of metalworking processes, formability analysis, mathematical modeling and case studies of individual processes are presented.

Applied Metal Forming: Including FEM Analysis describes metal forming theory and how experimental techniques can be used to study any metal forming operation with great accuracy. For each primary class of processes, such as forging, rolling, extrusion, wiredrawing, and sheet-metal forming, it explains how FEA (Finite Element Analysis) can be applied with great precision to characterize the forming condition and in this way optimize the processes. FEA has made it possible to build very realistic FEM-models of any metal forming process, including complex three-dimensional forming operations, in which complex products are shaped by complex dies. Thus, using FEA it is now possible to visualize any metal forming process and to study strain, stresses, and other forming conditions inside the parts being manufactured as they develop throughout the process.

The concept of virtual manufacturing has been developed in order to increase the industrial performances, being one of the most ef cient ways of reducing the m- ufacturing times and improving the quality of the products. Numerical simulation of metal forming processes, as a component of the virtual manufacturing process, has a very important contribution to the reduction of the lead time. The nite element method is currently the most widely used numerical procedure for s- ulating sheet metal forming processes. The accuracy of the simulation programs used in industry is in uenced by the constitutive models and the forming limit curves models incorporated in their structure. From the above discussion, we can distinguish a very strong connection between virtual manufacturing as a general concept, ?nite element method as a numerical analysis instrument and constitutive laws,aswellas forming limit curves as a speci city of the sheet metal forming processes. Consequently, the material modeling is strategic when models of reality have to be built. The book gives a synthetic presentation of the research performed in the eld of sheet metal forming simulation during more than 20 years by the members of three international teams: the Research Centre on Sheet Metal Forming—CERTETA (Technical University of Cluj-Napoca, Romania); AutoForm Company from Zürich, Switzerland and VOLVO automotive company from Sweden. The rst chapter presents an overview of different Finite Element (FE) formu- tions used for sheet metal forming simulation, now and in the past.

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

A follow-up to his popular Sheet Metal Fabrication, author Tim Remus taps into the talents of master craftsmen to bring you more techniques for forming aluminum and steel into the one-of-a-kind parts that make your street rod or custom cycle more than a "me too" machine. This book is lavishly illustrated with quality photographs while Remus takes you through a number of start-to-finish sequences with the finest metal workers in the field. If you strive build a truly unique machine, Advanced Sheet Metal Fabricationis the book for you.

The art of metal forming is an ancient one, as evidenced by the Greek and Roman helmets and cuirasses produced by the skill of early-day crafts- men. The wooden mallet, the metal hammer, and the leather sand bag used originally for hand forming of metals are still with us. With the advent of hand-operated machinery, a variety of hand brakes, benders, folders, rollers, crimpers, and rope-type drop hammers appeared and are still in use today. The development of power-driven machines brought out power hammers, power brakes, a multitude of presses, including hydraulic monsters (50,000 tons), wrappers, stretchers, steam and pneumatic hammers and the like. All are in use today in combination with tools and dies, some of which are rather sophisticated in nature. Some of the newer techniques of metal forming have been developed by the Manufacturing Engineering Laboratory of the Marshall Space Flight Center, and others by the aerospace industry companies.