Search Results for progressive die forming

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.

This chapter discusses the design and application of sheet forming presses. The discussion covers critical variables and design parameters, key components, basic machine configurations, and energy and load requirements. The chapter also discusses time-dependent characteristics, dimensional accuracy, and stiffness as well as die change procedures.

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 appendix is a glossary of terms and definitions associated with sheet metal forming.

This chapter describes the processes, applications, and limitations of forming and shaping various materials. It discusses bulk forming, hot working, cold working, sheet forming, and polymer and powder processing.

This chapter discusses the types of sensors used in sheet forming operations and the information they provide. It explains how force sensors protect equipment from overloads due to tool wear, friction, and misfeeds, how displacement and proximity sensors help to prevent die crashes, how acoustic emission, ultrasonic, and eddy current sensors detect tool breakage and part defects such as cracks, and how roller ball and optical sensors measure material flow. It also discusses the role of draw-in, wrinkle, oil-monitoring, and vision sensors and explains how material properties can be derived in real time from various sensor outputs.

This chapter discusses the design and operation of electromechanical servo-drive presses. It begins by comparing the operating flexibility of servo-press drives with that of their conventional counterparts. It then explains the difference between direct-drive and belt and screw-driven servo presses and describes some of the innovations and improvements made possible with high-torque servo motors. The chapter provides examples of how servo presses are used in blanking, warm forming, and other applications and compares the operating characteristics of two 1100-ton presses, one driven by servo motors, the other by a mechanical crank.

This chapter provides an overview of the blanking process and the forces and stresses involved. It discusses the factors that affect part quality and tool life, including punch and die geometry, stagger, clearance, and wear as well as punch velocities, misalignment, and snap-thru forces. It also discusses ultra-high-speed blanking, fine blanking, and shearing, and the use finite-element simulations to predict part edge quality.

This chapter describes the equipment and processes used to form titanium alloy parts. It discusses the advantages and disadvantages of hot and cold forming, the factors that influence formability, and the effect of forming temperature and lubricants. It describes common processes, including brake forming, stretch forming, deep drawing, and spin forming as well as roll forming, drop-hammer forming, tube bulging and bending, and superplastic forming. It also discusses dimpling and joggling and the use of hot sizing to correct springback.

This chapter describes sheet metal forming operations, including cutting, blanking, piercing, and bending as well as deep drawing, spinning, press-brake and stretch forming, fluid forming, and drop hammer and electromagnetic forming. It also discusses the selection and use of die materials and lubricants along with superplastic forming techniques.

This chapter defines near-net shape forging as the process of forging parts close to their final dimensions such that little machining or only grinding is required as a final step. It then describes the causes of dimensional variations in forging, including die deflection, press deflection, and process inconsistencies, and discusses related innovations.

This chapter describes the nature of the problems arising from using advanced high-strength steels (AHSS) and discusses potential remedies to minimize the adverse effects that may limit the adoption of AHSS in the automotive industry. The discussion provides information on press energy, springback, residual stress, die wear, hot forming, downgaging limits, welding, binders, draw beads, and tool material wear.

This chapter describes the nature of the problems arising from using advanced high-strength steels, including limited formability, reduced weldability, increased springback, elevated press tonnage, and accelerated die wear, and discusses potential remedies to minimize the adverse effects that may limit the adoption of AHSS in the automotive industry.

This chapter assesses the benefits of using a solid immersion lens (SIL) to detect faults in ICs via optical imaging and laser-stimulation techniques. It discusses the advantages and limitations of different types of SILs and their effect on spatial resolution, spot size, focus depth, and collection efficiency. It also provides a brief overview of technical challenges at the die level.

This chapter provides a concise, design-oriented summary of more than 30 sheet forming processes within the categories of bending and flanging, stretch forming, deep drawing, blank preparation, and incremental and hybrid forming. Each summary includes a description and diagram of the process and a bullet-point list identifying relevant equipment, materials, variations, and applications. The chapter also discusses critical process variables, interactions, and components and the classification of sheet metal parts based on geometry.

Almost all metals and alloys are produced from liquids by solidification. For both castings and wrought products, the solidification process has a major influence on both the microstructure and mechanical properties of the final product. This chapter discusses the three zones that a metal cast into a mold can have: a chill zone, a zone containing columnar grains, and a center-equiaxed grain zone. Since the way in which alloys partition on freezing, it follows that all castings are segregated to different categories. The different types of segregation discussed include normal, gravity, micro, and inverse. The chapter also provides information on grain refinement and secondary dendrite arm spacing and porosity and shrinkage in castings. It concludes with a brief overview of six of the most important casting processes in industries: sand casting, plaster mold casting, evaporative pattern casting, investment casting, permanent mold casting, and die casting.

The conversion of feedstock into a shape involves the application of heat and pressure, and possibly solvents. This chapter discusses the operating principle, advantages, limitations, and applications of such shaping processes, namely additive manufacturing, cold isostatic pressing, die compaction, extrusion, injection molding, slip casting, slurry processes, and tape casting. Information on equipment setup, requirements, and the various factors influencing these processes are described. In addition, the chapter provides information on novel approaches and processing costs applicable to these shaping processes.

This chapter describes the general characteristics of two commonly classified metalworking processes, namely hot working and cold working. Primary metalworking processes, such as the bulk deformation processes used to conduct the initial breakdown of cast ingots, are always conducted hot. Secondary processes, which are used to produce the final product shape, are conducted either hot or cold. The chapter discusses the primary objectives, principal types, advantages, and disadvantages of both primary and secondary metalworking processes. They are rolling, forging, extrusion, sheet metal forming processes, blanking and piercing, bending, stretch forming, drawing, rubber pad forming, and superplastic forming.