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quick plastic forming
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Image
Published: 01 January 2006
Fig. 3 Schematic illustration of the quick plastic forming cell used for the high-production superplastic forming of aluminum-magnesium sheet alloys in the automotive industry. Source: Ref 5
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Published: 01 January 2006
Image
Published: 01 January 2006
Fig. 46 The quick plastic forming (QPF) process can be run with integrally heated dies as for warm forming applications.
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Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005147
EISBN: 978-1-62708-186-3
... drawing, superplastic forming/diffusion bonding, forging, extrusion, and dieless drawing. It provides information on superelastic forming equipment and tooling. The article explains the thinning characteristics and quick plastic forming and its technological elements. It describes the manufacturing...
Abstract
This article discusses many of the processes and related considerations involved in the forming of superplastic sheet metal parts. It reviews the requirements for superplasticity and describes the characteristics of superplastic metals. The characterization of superplastic behavior includes the characterization of plastic flow, internal cavitation, and fracture behavior. Processing variables needed for the overall characterization of superplastic behavior are summarized. The article discusses the superplastic forming methods, namely, blow forming, vacuum forming, thermoforming, deep drawing, superplastic forming/diffusion bonding, forging, extrusion, and dieless drawing. It provides information on superelastic forming equipment and tooling. The article explains the thinning characteristics and quick plastic forming and its technological elements. It describes the manufacturing practice of the process. The article concludes with a discussion on the superplastic behavior in iron-base alloys.
Image
Published: 30 November 2018
Fig. 19 Deformation mechanism map of aluminum alloy 5083 with superplastic forming, quick plastic forming, and hot stamping. GBS = grain boundary sliding, SD = slip deformation, PLB = persistent Lüders, or slip, bands. Source: Ref 10
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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
... ) and somewhat lower temperatures. Perhaps the largest-volume use of the new approaches is that recently introduced by General Motors for the forming of 5083 aluminum-magnesium alloy sheet and referred to as quick plastic forming (QPF) ( Ref 5 , 6 ). As in other SPF techniques, SPF shaping usually involves...
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: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006527
EISBN: 978-1-62708-207-5
... operations on aluminum and its alloys. During plastic forming of metals, most of the work is converted to heat, but some of energy is stored in the microstructure in the form of dislocations that cause hardening. For aluminum alloys, the stored energy per unit volume due to plastic strain (ε) for deformation...
Abstract
Aluminum and its alloys are among the more formable materials of commonly fabricated metals. This article discusses the formability, bendability, and springback of aluminum and its alloys. It describes the forming limit diagrams that illustrate the biaxial combinations of strain that can occur without splitting. The article reviews various bending methods, such as draw, compression, ram and press, roll, and stretch or tension bending. It describes the process variations of incremental sheet forming (ISF), such as single-point incremental forming, two-point incremental forming, and kinematic incremental sheet forming. The article concludes with a discussion on spinning, warm forming, and superplastic forming.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006761
EISBN: 978-1-62708-295-2
... (Rockwell B range) in ASTM International E 140 are the approximate conversion tables for nonaustenitic steels. These data are commonly reproduced in large, poster-sized wall hangings by hardness-testing companies or in small plastic cards used for quick reference. Sometimes these reproductions state...
Abstract
Mechanical testing is an evaluative tool used by the failure analyst to collect data regarding the macro- and micromechanical properties of the materials being examined. This article provides information on a few important considerations regarding mechanical testing that the failure analyst must keep in mind. These considerations include the test location and orientation, the use of raw material certifications, the certifications potentially not representing the hardware, and the determination of valid test results. The article introduces the concepts of various mechanical testing techniques and discusses the advantages and limitations of each technique when used in failure analysis. The focus is on various types of static load testing, hardness testing, and impact testing. The testing types covered include uniaxial tension testing, uniaxial compression testing, bend testing, hardness testing, macroindentation hardness, microindentation hardness, and the impact toughness test.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006868
EISBN: 978-1-62708-395-9
... of modern materials, the breadth of potential solutions (via part and/or component or assembly design) provided through the use of plastics is second to none. A quick review of the UL Prospector Plastics Database shows an incredible 85,000 or so formulations of plastic materials available. In addition...
Abstract
This article presents the benefits of selecting plastics for products to be manufactured. It discusses the four key considerations for plastic part design: material, process, tooling, and design. The article provides a detailed discussion of the development sequence for plastic parts. The basis for the development sequence is twofold: first, to create the best solution for the application, and second, to minimize potential project risks through careful and thoughtful work habits.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.9781627082952
EISBN: 978-1-62708-295-2
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005154
EISBN: 978-1-62708-186-3
... at the corners due to greater deformation in these regions. The effects of process parameters (tool size, feed rate, plastic anisotropy) on formability during incremental forming have also been determined ( Ref 17 ). The formability of aluminum sheet under various forming conditions is considered in Ref 18...
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.
Book Chapter
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003016
EISBN: 978-1-62708-200-6
... reduction, and/or cost reduction. Machinery and Processing Methods Extrusion blow molding is the primary processing method used for engineering thermoplastics today. The process forms a hollow tube of molten plastic material called a parison. The parison formation is either continuous or intermittent...
Abstract
Blow molding has emerged as a commercially viable process for manufacturing parts for nonpackaging/industrial markets. This article discusses the machinery required, processing methods, mold types, process parameters, part designs and material distribution of blow molding. It provides an outline of the parison programming system equipped with blow molders to control the parison thickness. The article describes factors that are usually considered to minimize material distribution problems, namely, design, material selection, process control, part performance, and cost.
Series: ASM Handbook
Volume: 23
Publisher: ASM International
Published: 01 June 2012
DOI: 10.31399/asm.hb.v23.a0005672
EISBN: 978-1-62708-198-6
.... There are several treatment methods available to modify polymer surfaces and effectively increase their surface energy to make them more amenable to adhesive bonding. Conventional plastic surface treatments include corona and flame treatments. Corona treatment is a quick and inexpensive method. This process...
Abstract
This article provides an overview of curing techniques, adhesive chemistries, surface preparation, adhesive selection, and medical applications of adhesives. The curing techniques are classified into moisture, irradiation, heat, and anaerobic. The article highlights the common types of curable adhesives used for medical device assemblies, including acrylics, cyanoacrylates, epoxies, urethanes, and silicones. Other forms of adhesives, such as hot melts, bioadhesives, and pressure-sensitive adhesives, are also discussed. The typical characteristics and applications of biocompatible medical device adhesives are listed in a table. The article concludes with a section on the selection of materials for medical adhesives.
Book: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006842
EISBN: 978-1-62708-387-4
... concentration Likewise, many manufacturing and material problems found in metals are also observed or have a corollary in plastics. Weldments are a trouble-prone area for metals, as are weld lines or knit lines in molded plastics ( Fig. 12 ). High residual stresses can result from metal forming, heat...
Abstract
This article addresses macroscale fracture appearances, microscale fracture-surface appearances or morphologies, fracture mechanisms, and those factors that influence fractures and fracture appearances. Some of the macroscopic and microscopic features identified by the failure analyst to evaluate the fracture surfaces of metals and plastics are described and compared.
Series: ASM Handbook
Volume: 8
Publisher: ASM International
Published: 01 January 2000
DOI: 10.31399/asm.hb.v08.a0003270
EISBN: 978-1-62708-176-4
... deformation, only the shear stress may be considered responsible for the plastic strain. The stress field in the deformed material volume may therefore be represented by the maximum shear stresses in the form of slip lines (see Fig. 2 ). These lines should not be confused with the slip lines associated...
Abstract
Hardness testing is perhaps the simplest and the least expensive method of mechanically characterizing a material. This article provides an overview of the principles of hardness testing. It compares Brinell with Meyer hardness testing and hardness testing of fully cold worked metals with fully annealed metals. The article discusses the plastic deformation of ideal plastic metals under an indenter, by a flat punch, and by spherical indenters. The classification of the hardness tests using various criteria, including type of measurement, magnitude of indentation load, and nature of the test, is also provided.
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005168
EISBN: 978-1-62708-186-3
... Abstract This article discusses the numerical simulation of the forming of aluminum alloy sheet metals. The macroscopic and microscopic aspects of the plastic behavior of aluminum alloys are reviewed. The article presents constitutive equations suitable for the description of aluminum alloy...
Abstract
This article discusses the numerical simulation of the forming of aluminum alloy sheet metals. The macroscopic and microscopic aspects of the plastic behavior of aluminum alloys are reviewed. The article presents constitutive equations suitable for the description of aluminum alloy sheets. It explains testing procedures and analysis methods that are used to measure the relevant data needed to identify the material coefficients. The article describes the various formulations of finite element methods used in sheet metal forming process simulations. Stress-integration procedures for both continuum and crystal-plasticity mechanics are also discussed. The article also provides various examples that illustrate the simulation of aluminum sheet forming.
Book: Fatigue and Fracture
Series: ASM Handbook
Volume: 19
Publisher: ASM International
Published: 01 January 1996
DOI: 10.31399/asm.hb.v19.a0002355
EISBN: 978-1-62708-193-1
... plastic strain amplitude, a very slight increase in strain amplitude resulted in quick formation of intensive slip markings on the surface. Neumann ( Ref 42 ) cycled single crystals with linearly increasing stress amplitude. The plastic strain amplitude showed very strong maxima during testing...
Abstract
This article presents an overview of fatigue crack nucleation from the point of view of the material microstructure and its evolution during cycling. It describes the sites of microcrack nucleation at the free surfaces. The article discusses the relation of dislocation structures and surface relief and reviews the mechanisms of crack nucleation. The damage of material due to crack nucleation, the extent (in terms of the number of cycles) of the nucleation stage, and the factors influencing crack nucleation are discussed.
Book Chapter
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005251
EISBN: 978-1-62708-187-0
... plastic films along the top and bottom sand surfaces of the cope and the drag molds and then vacuum applied to the sand medium of the cope and the drag ( Fig. 2 ). The plastic film along the top of the drag mold and the bottom of the cope mold is softened by heating and then formed on an appropriate...
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006927
EISBN: 978-1-62708-395-9
... general design rules for the plastic forming processes covered. It also discusses the steps involved in design validation and verification. plastic design plastic forming tooling DESIGN of a plastic part needing to be formed must consider the material, the process, and the tooling...
Abstract
This article provides background information needed by design engineers to create part designs optimized for plastics and plastic manufacturing processes. It describes the four essential elements of plastic part development, namely, material, process, tooling, and design, and provides general design rules for the plastic forming processes covered. It also discusses the steps involved in design validation and verification.
Book: Machining
Series: ASM Handbook
Volume: 16
Publisher: ASM International
Published: 01 January 1989
DOI: 10.31399/asm.hb.v16.a0002117
EISBN: 978-1-62708-188-7
... deformation), which forms the chip. The chip passes over the rake face of the cutting tool and receives additional deformation (called the secondary deformation) because of the shearing and sliding of the chip against the tool. These two plastic deformation processes have a mutual dependence. The material...
Abstract
The relative motion between the tool and the workpiece during cutting compresses the work material near the tool and induces a shear deformation that forms the chip. This article discusses the fundamental nature of the deformation process associated with machining. It describes the mechanics of the machining process, and presents the principles of the orthogonal cutting model. The article also analyzes the effect of workpiece properties on chip formation.
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