This chapter discusses the use of finite-element modeling in forging design. It describes key modeling parameters and inputs, mesh generation and computation time, and process modeling outputs such as metal flow, strain rate, loading profiles, and microstructure. It also includes a variety of application examples.

This chapter discusses the use of finite-element methods for modeling cold forging processes. The discussion covers process modeling inputs, such as geometric parameters, material properties, and interface conditions, and includes several application examples.

This chapter discusses the use of modeling and simulation technology in the development of sheet metal forming processes. It describes the five major steps involved in finite-element analysis and the various ways functions of interest can be approximated at each point or node in a finite-element mesh. It explains how to obtain input data, what to expect in terms of output data, and how to predict specific types of defects. In addition, it presents several case studies demonstrating the use of finite elements in blanking and piercing, deep drawing of round and rectangular cups, progressive die sequencing, blank holder force optimization, sheet hydroforming, hot stamping, and springback and bending of advanced high-strength steels. It also discusses the factors that affect the accuracy of finite element simulations such as springback, thickness variations, and nonisothermal effects.

This chapter provides a detailed analysis of the deep drawing process. It begins by explaining that different areas of the workpiece are subjected to different types of forces and loads, equating to five deformation zones. After describing the various zones, it discusses the effect of key process parameters including the draw ratio, material properties, geometry, interface conditions, equipment operating speed, and tooling. It then walks through the steps involved in predicting stress, strain, and punch force using the slab method and finite element analysis and presents the results of simulations conducted to assess the influence of blank diameter, thickness, and holding force as well as strain-hardening and strength coefficients. It also discusses the cause of defects in deep drawn rectangular cups and presents the case study of a deep drawn rectangular cup made from an aluminum blank.

This appendix presents a close-form solution to determine the stress distribution around a hole of any shape or size in a strip of any material of any width. It also compares the close-form equation to classical solutions and the results of finite element analysis, demonstrating near perfect matches in each case.

This chapter presents two case studies; one demonstrating the use of finite-element analysis (FEA) in the design of a progressive die forming operation, the other explaining how software simulations helped engineers reduce thinning and eliminate cracking and deformation observed in clutch hubs formed using a three-step transfer die process. It also discusses the role of FEA and commercial software in the design of progressive dies.

Hot stamping is a forming process for ultrahigh-strength steels (UHSS) that maximizes formability while minimizing springback. This chapter covers several aspects of hot stamping, including the methods used, the effect of process variables, and the role of finite-element analysis in process development and die design. It also discusses heating methods, cooling mechanisms, and the role of coatings in preventing oxidation.

This chapter describes a sheet metal forming method, called hydroforming, that uses pressurized liquid and a shaped punch or die. It discusses the advantages and disadvantages of the two approaches, the effect of process variations, and tooling modifications intended to reduce sheet bulging. It identifies the factors that influence part quality and explains how finite-element analysis can be used to optimize hydroforming operations. It also discusses the economics of sheet hydroforming and presents several application examples.

This chapter provides an overview of how the disciplines of design, material, and manufacturing contribute to engineering for functional performance. It describes the interaction of product designers and casting engineers in product development. It discusses the consequences of component failure, uncertainty in data and assumptions, and selection of the factor of safety. The chapter also presents an overview of the functional requirements for product performance and provides an overview of product design development. It also presents a partial list of the different tests that are performed on prototypes and examples of product testing. The chapter describes the requirements of a traceability system.