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Sheet-metal forming system containing a flexible binder with individually c...
Available to PurchasePublished: 01 January 2006
Fig. 9 Sheet-metal forming system containing a flexible binder with individually controlled hydraulic cylinders. Source: Ref 31
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Book Chapter
Rapid Prototyping for Sheet-Metal Forming
Available to PurchaseSeries: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005154
EISBN: 978-1-62708-186-3
... of the technologies used for RP and low-volume production of sheet-metal parts. It discusses low-cost tooling and flexible sheet-forming processes and reviews the various aspects of incremental sheet forming. dieless NC forming flexible sheet-forming incremental sheet forming low-cost tooling rapid...
Abstract
Rapid prototyping (RP) techniques in the sheet-metal forming industry is developed to quickly test the form and fit of new sheet-metal products on a prototype basis as well as for production runs characterized by small lot sizes. This article provides an overview of some of the technologies used for RP and low-volume production of sheet-metal parts. It discusses low-cost tooling and flexible sheet-forming processes and reviews the various aspects of incremental sheet forming.
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005100
EISBN: 978-1-62708-186-3
..., design, and control of sheet-forming processes. advanced high-strength steels aluminum dieless forming expensive steel dies flexible manufacturing high-velocity metal forming magnesium alloys peen forming process simulation rapid prototyping rubber-pad forming sheet forming superplastic...
Abstract
Sheet forming comprises deformation processes in which a metal blank is shaped by tools or dies, primarily under the action of tensile stresses. This article discusses the classification of sheet-forming processes for obtaining desired dimensional features. It describes different process-related developments, namely, superplastic forming of aluminum, forming of tailor-welded blanks, rubber-pad forming, and high-velocity metal forming. The article explains cost-effective approaches of evaluating tooling designs prior to the manufacture of expensive steel dies and dieless forming techniques such as thermal forming and peen forming. It provides information on the application of advanced high-strength steels, magnesium alloys, and various ultrafine-grain materials for superplastic sheet forming. The article concludes with information on the development and application of simulation, design, and control of sheet-forming processes.
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005101
EISBN: 978-1-62708-186-3
... Abstract Sheet-forming processes provide considerable geometric and material flexibility in meeting these requirements, and design of parts for sheet forming must take into account these benefits as well as the limitations of the processes. This article reviews the basic forming operations...
Abstract
Sheet-forming processes provide considerable geometric and material flexibility in meeting these requirements, and design of parts for sheet forming must take into account these benefits as well as the limitations of the processes. This article reviews the basic forming operations and their general geometric features. These operations include hole making, flanging, bead and rib forming, and stretching and drawing for shallow or deep recesses. The article illustrates the general approach to design for sheet forming and the considerations that must be made for material savings and manufacturing ease, in addition to part function. It concludes with information on reducing the amount of scrap in sheet-forming operations.
Book Chapter
Presses and Auxiliary Equipment for Forming of Sheet Metal
Available to PurchaseSeries: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005112
EISBN: 978-1-62708-186-3
... presses, and flexible-die forming presses. automatic handling equipment die casting machines fine-blanking flexible-die forming presses gap-frame presses high-production presses hydraulic presses hydraulically powered machines mechanical presses mechanically powered machines multiple-slide...
Abstract
This article describes the various types of press construction and the factors that influence the selection of mechanically or hydraulically powered machines for producing parts from sheet metal. Presses are broadly classified, according to the type of frame used in their construction, into two main groups: gap-frame presses and straight-side presses. The article describes the various components of mechanical presses and hydraulic presses. It discusses important factors, such as the size, force, energy, and speed requirements, that influence the selection of a press. The article describes the roles of automatic handling equipment that can be categorized as feeding equipment, unloading equipment, and transfer equipment. It concludes with information on the common types of high-production presses, such as dieing machines, multiple-slide machines, transfer presses, fine blanking presses, and flexible-die forming presses.
Image
Flexible multipoint forming in which the die pins replace both die and stam...
Available to PurchasePublished: 01 January 2006
Fig. 3 Flexible multipoint forming in which the die pins replace both die and stamp. (a) Different modes of multipoint forming can be either passive or produces an active pressure toward the stamp. (b) Flexible multipoint forming of 16 mm (0.63 in.) stainless steel sheet. Courtesy
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Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005164
EISBN: 978-1-62708-186-3
... The wide variety of organic coatings available prevents any detailed discussion of the formability of each separate class of organic material used to coat coated sheet steels. Some organic coatings are flexible enough to withstand any forming operations that will not cause fracture in the steel substrate...
Abstract
This article provides an overview of some common sheet steel coatings available. It discusses the formability differences between coated and bare steel and provides some general guidelines on the forming of coated steels. Coated steels are classified according to the nature of the substrate, the type of coating, and the method used for its application. The article describes various coating types for steels such as zinc-coated steels, aluminum-coated steels, tin-coated steels, terne-coated steels, and organic-coated steels.
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005132
EISBN: 978-1-62708-186-3
... G. , “Single Piece Wing Skin Utilization via Advanced Peen Forming Technologies,” Seventh International Conference on Shot Peening ( Warsaw, Poland ), 1999 25. Kopp R. and Schulz J. , Flexible Sheet Forming Technology by Double-Sided Simultaneous Shot Peen Forming , CIRP...
Abstract
Shot peen forming is a manufacturing process in which local compressive residual stresses form thin sheet metals and structural components in one or more dimensions. This article discusses the principle of the process with an emphasis on fundamental mechanisms. It presents the basic considerations in the simulation of shot peen forming and provides information on single impact and multiple-impact peening simulations. The article describes the equipment and tooling used in the process. It also analyzes the influence of process parameters on shot peen forming and illustrates possible shapes and contours, which are producible by shot peen forming. The article concludes with a table that presents typical peen forming applications in the aircraft and aerospace industries.
Book Chapter
Brazing With Clad Brazing Materials
Available to PurchaseSeries: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0001392
EISBN: 978-1-62708-173-3
... filler metal, which can be in the form of a foil, a paste, or a powder that has been consolidated into a sheet using a polymer carrier, is inserted between the plate and fin, and a multiple stack of plate, brazing foil, and fin is fixtured for brazing in a furnace. This complex assembly requires...
Abstract
This article focuses on clad brazing material, which is defined as any base material or alloy that is clad with an appropriate lower-melting-point brazing filler metal. It provides information on typical clad brazing strip products in a tabular form and lists the advantages of using clad brazing materials. The article compares the steps in using brazing preforms to fabricate a brazed assembly with the steps involved in using clad brazing materials. It concludes with a discussion on design and manufacturing considerations, during brazing with clad brazing materials.
Book: Corrosion: Materials
Series: ASM Handbook
Volume: 13B
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v13b.a0003809
EISBN: 978-1-62708-183-2
... application, the paint must be flexible to endure the strains induced in subsequent forming operations. It must not craze on bending, a condition that would compromise corrosion resistance. In addition, the bend radii in the forming stages are often more severe than for the final part. The coating must...
Abstract
This article describes the paint systems generally used to protect steel structures, steel sheet, and bridges from corrosion, and how they deter corrosion. It provides a discussion on the basic design criteria of steel structures for corrosion protection. The article also explains the differences between prepaint and postpaint, and the steps involved in prepaint processing of steel. It presents the selection guideline for paint system evaluation. The advantages of corrosion protection are also discussed.
Book: Composites
Series: ASM Handbook Archive
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003405
EISBN: 978-1-62708-195-5
... is required to achieve tolerance/configuration control, while flexibility ensures good compaction. Bag-Side Elastomeric Cauls Commercially available caul systems are provided in two forms: Form 1: calendered reinforced and unreinforced sheets of rubber Form 2: calendered unreinforced...
Abstract
Elastomeric tooling uses rubber details to generate required molding pressure or to serve as a pressure intensifier during composite part curing cycles. This article discusses the various aspects of the forms of commercially available bag-side elastomeric caul systems. It describes the two basic methods, such as the trapped or fixed-volume rubber method and the variable-volume rubber method, of elastomeric tooling, which use the principles of thermal expansion molding. The significant properties and controlling equations that are required to characterize elastomeric tooling material are also discussed.
Book Chapter
Rotational Molding
Available to PurchaseSeries: ASM Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003017
EISBN: 978-1-62708-200-6
... regulations for food contact. Polyvinyl chloride (PVC) resins have been used in rotational molding longer than any other resin. They are available in liquid form as vinyl plastisol or in powder form. They can be formulated to produce flexible to semirigid products. They are moderate in cost and are used...
Abstract
Rotational molding is a simple but unique process that has the capability of producing small to large hollow items with very uniform wall thicknesses. Providing an overview of the operating principles of rotational molding, this article discusses the key selection factors, including function and property requirements for resins and additives; size, shape, design, and cost of molded parts; equipment type and size; and the type of mold to be used. Commonly used molds include cast aluminum, fabricated sheet metal, nickel deposit, machined aluminum, silicone, fiberglass, and prototype molds.
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005130
EISBN: 978-1-62708-186-3
.... Male A.T. , Li P.J. , Chen Y.W. , and Zhang Y.M. , Flexible Forming of Sheet Metal Using Plasma Arc , Sheet Metal 1999, Proc. International Conference ( Erlangen, Germany ), p 555 – 560 7. Li P.J. , Chen Y.W. , Male A.T. , and Zhang Y.M. , Flexible...
Abstract
This article begins with a discussion on the energy sources used for thermal forming. These include electric induction coil, gas flame, plasma torch, and laser beam. The article discusses the mechanisms of forming and different modes of deformation. It describes the effect of process and material parameters on forming and the effect of metallurgical changes on mechanical property and microstructure of stainless steel. The article concludes with information on the applications of thermal forming.
Book Chapter
Rubber Coatings and Linings
Available to PurchaseSeries: ASM Handbook
Volume: 13A
Publisher: ASM International
Published: 01 January 2003
DOI: 10.31399/asm.hb.v13a.a0003695
EISBN: 978-1-62708-182-5
... for corrosion protection is discussed in the article “Organic Coatings and Linings” in this Volume. Rubber, in the form of prefabricated sheets, has been used successfully as a lining material in storage tanks ( Fig. 1 ), water boxes, condensers, flue gas desulfurization (FGD) units, chemical scrubbers...
Abstract
This article presents a detailed discussion on the relative performance properties of principal rubber types used in lining applications together with their application, vulcanization and inspection techniques, and material and installation costs.
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005122
EISBN: 978-1-62708-186-3
... • Hardt D.E. , Boyce M.C. , and Walczyk D.F. , A Flexible Forming System for Rapid Response Production of Sheet Metal Parts , Proceedings of IBEC '93 ( Detroit, MI ), Society of Automotive Engineers, 1993 , p 61 – 69 • Hosford W. and Caddell R. , Metal Forming...
Abstract
Stretch forming is the forming of sheet, bars, and rolled or extruded sections over a die or form block of the required shape while the workpiece is held in tension. This article discusses the applicability, advantages, and machines and accessories of stretch forming. It provides a detailed discussion on four methods of stretch forming, namely, stretch draw forming, stretch wrapping, compression forming, and radial draw forming.
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005121
EISBN: 978-1-62708-186-3
... technology is currently being used to successfully deep draw stainless steel double sinks. Fig. 14 Schematic of a rigid sheet metal forming system Fig. 15 Flexible binder with individually controlled hydraulic cylinders Fig. 16 Wrinkles obtained using nonoptimized pin forces...
Abstract
This article illustrates the mechanics of the deep drawing of a cylindrical cup. It discusses the fundamentals of drawing and drawability. Sheet metal is drawn in either hydraulic or mechanical presses. The article summarizes the defects in drawing and factors considered in press selection for drawing. It explains the types of dies used for drawing sheet metal and the effects of process variables and material variables on deep drawing. The process variables that affect the success or failure of a deep-drawing operation include the punch and die radii, punch-to-die clearance, press speed, lubrication, and type of restraint of metal flow used. The article describes the process of redrawing and ironing of metals. Drawing of workpieces with flanges and drawing of hemispheres are also illustrated. The article also provides information on the reducing of drawn shells, methods for expanding portions of drawn workpieces, trimming, and deep drawing using fluid-forming presses.
Book Chapter
Mechanical Joining by Forming
Available to PurchaseSeries: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0009154
EISBN: 978-1-62708-186-3
... of water forms an electrolytic cell. This type of corrosion can be avoided if the rivet is manufactured from the same material as the sheets being joined. At early stages of finite-element modeling of SPR, finite-element analysis in two dimensions was used to calculate setting forces, displacements...
Abstract
Mechanical joining by forming includes all processes where parts being joined are formed locally and sometimes fully. This article focuses on the types, advantages, disadvantages, and applications of the various mechanical joining methods, namely, riveting, crimping, clinching, and self-pierce riveting.
Book Chapter
Rubber-Pad Forming and Hydroforming
Available to PurchaseSeries: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005124
EISBN: 978-1-62708-186-3
... Abstract This article focuses on the three basic groups of flexible-die forming methods: rubber pad, fluid cell, and fluid forming. It provides information on the Guerin process, the Verson-Wheelon process, the trapped-rubber process, the Marform process, the Hydroform process, the SAAB process...
Abstract
This article focuses on the three basic groups of flexible-die forming methods: rubber pad, fluid cell, and fluid forming. It provides information on the Guerin process, the Verson-Wheelon process, the trapped-rubber process, the Marform process, the Hydroform process, the SAAB process, and the Demarest process. The article provides a discussion on the procedures of these processes, as well as the presses and tools used. It describes the methods of hydraulic forming of thin metal parts, namely, hydraulic forming with diaphragm, hydraulic forming with gasket and pressure control, and hydrobuckling.
Series: ASM Handbook
Volume: 5B
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v05b.a0006027
EISBN: 978-1-62708-172-6
... to a preheated substrate. The molten particles impinge on the substrate, flattening and solidifying into an interlaced network of splats . The thickness of the coating is governed by the number of spray passes. Rubber Linings Rubber, in the form of prefabricated sheets, has been used successfully...
Abstract
This article provides a brief discussion on the common types of overlayers that can be used on a metal surface to protect it from corrosion. These overlayers include phosphate, chromate, and chromate-free conversion coatings; hot dip galvanizing; cementitious linings; glass and porcelain enamels; electroplating; thermal spray coatings; and rubber linings.
Book Chapter
Relationship between Materials Selection and Processing
Available to PurchaseSeries: ASM Handbook
Volume: 20
Publisher: ASM International
Published: 01 January 1997
DOI: 10.31399/asm.hb.v20.a0002455
EISBN: 978-1-62708-194-8
..., Vol 14, p 75 Sheet metal forming 3D 3 1 3 4 1 AHB, Vol 14, p 445 Rolling 2D 5 3 4 3 2 AHB, Vol 14, p 343 Extrusion 2D 5 3 4 3 2 AHB, Vol 14, p 315 Superplastic forming 3D 1 1 5 4 1 AHB, Vol 14, p 852 Thermoforming 3D 3 2 3 2 3 EMH, Vol 2, p 399 Blow...
Abstract
The selection of the best material for a particular design is intimately associated with the decisions of how to process the material or manufacture a part. This article describes the basic characteristics of manufacturing processes such as material factors, shape factors, and process factors. The influence of materials on the manufacturing cost is described with a specific example. The article discusses the design for manufacturability to minimize the total number of parts, use readily processed materials, and eliminate machining and finishing operations. It reviews the factors influencing the selection of a material for production, including material composition, heat-treated condition, surface finish, and cost of material. The article describes the material characteristics, such as terms formability, workability, castability, machinability, and weldability, that aid or hinder the production of a part without defects.
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