This article describes strain analysis techniques for troubleshooting formability and process discrepancies throughout a tooling development and production stamping cycle. The techniques include strain calculations of a flat blank, forming limit curve, and forming limit diagram. The article describes the types of strain analysis, namely, thinning strain analysis and circle grid strain analysis. It also provides information on the applications of the thinning strain analysis.

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.

Integrated computational materials engineering refers to the use of computer simulations that integrate mathematical models of complex metallurgical processes with computer models used in component and process design. This article outlines an example of a computer-aided engineering tool, such as virtual aluminum castings (VAC), developed and implemented for quickly developing durable cast aluminum power train components. It describes the procedures for the model development of the VAC system. These procedures include linking the manufacturing process to microstructure, linking microstructures to mechanical properties, linking material properties to performance prediction, and model validation and integration into the engineering process. The article discusses the benefits of the VAC system in process selection, process optimization, and improving the component design criteria.

The primary goal of quality control in electron beam (EB) welding is to consistently produce defect-free and structurally sound welds. This article discusses the common procedures for controlling the EB welding process, the control of the essential machine parameters, and the introduction of closed-loop controls and diagnostic feedback systems in the EB welding systems. It reviews the beam diagnostic tools that interrogate the beam to produce a reconstruction of the power density distribution and provide additional information on the size and shape of the EB. Knowledge of these beam parameters can be used to improve process understanding and control. The article also describes the application areas of beam diagnostics: machine characterization, weld parameter transfer, and weld quality control.

This article discusses the mechanics of chip formation and reviews the analytical modeling of the chip formation process by high-speed machining within the framework of continuum mechanics. It examines the relationship between the various high-speed machining parameters. The article describes the cutting tool systems for aluminum alloys, steel, superalloys, and titanium alloys and provides an overview of the alternative cutting tool geometries for increasing tool life. It highlights the factors considered by companies planning to employ high-speed machining systems and concludes with information on the applications of high-speed machining.

This article discusses process simulation applications such as casting, powder metallurgy, machining, surface engineering, heat treatment, and joining. The implementation of modeling and simulation tools requires accurate descriptions of material properties and process boundary conditions. The article describes the role of input data and boundary conditions for process simulations. It provides information on the critical enablers of computational materials engineering, such as the computational speed, computational materials engineering software/hardware supply chain, and cost structure for virtual versus physical manufacturing and analysis.

This article focuses on friction stir welding (FSW), where frictional heating and displacement of the plastic material occurs by a rapidly rotating tool traversing the weld joint. Much of the research activity early on pertained to issues related to understanding the process, such as learning about material flow, heat generation, microstructure development, and many other fundamental issues. The article summarizes the results of the research, describing the aspects of how FSW actually accomplishes sound joints in metals without melting them. It discusses the FSW process variations and the practical aspects of heat generation. The article provides information on the effect of welding on material properties and typical alloys in FSW applications. The alloys include 6061 aluminum, 5083 aluminum, 2xxx aluminum, and 7xxx aluminum alloys. The article concludes with a discussion on FSW equipment.

This article discusses the development of a welding procedure for friction stir welding (FSW), including the process of defining a preliminary procedure, the optimization of parameters, the development of supporting data, and other key features to ensure a successful procedure. The critical features of FSW tool design, initial process parameters, systematic welding trials, and robustness testing are reviewed. The article provides information on the common features of welding procedure qualification. It also includes a table that lists the procedures used in the production of sound friction stir welds in various aluminum alloys.

This article presents the definitions of creativity and creative thinking. It discusses the various stages in creative problem solving process. The stages include understanding the product problem, transforming the product, and breaking the product into subfunctional groups. The article provides a description of concept generating tools that are often arbitrarily described as individual or group tools. It concludes with a discussion on the application of creative concept generation in product design.

This article focuses on the technology breakthroughs that make forming simulation a routine work throughout the industry. It discusses many forms of the computer-aided engineering (CAE) methodology. The article describes several failure criteria to predict the failure of sheet metal. It explains the numerical procedure for sheet metal forming and reviews the important technical issues in CAE simulations. The article provides information on the applications and process of metal-forming simulation. It also reviews the capabilities of major systems that are popular among sheet metal forming users worldwide.

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.

Design and analysis of electrical/electronic systems and components tends to be different from the corresponding process for most mechanical and hydraulic systems. This article provides an overview of three overlapping phases followed in electrical design: functional, electrical, and physical. It also presents information on the simulation and testing carried out to evaluate the design behavior.

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.

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.