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Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2012
DOI: 10.31399/asm.tb.smfpa.t53500249
EISBN: 978-1-62708-317-1
... Abstract Sheet metal spinning is a forming technique that produces axially symmetric hollow bodies with nearly any contour. It is often used in combination with flow forming and shear spinning to manufacture a wide range of complex parts. This chapter describes the operating principles, stress...
Abstract
Sheet metal spinning is a forming technique that produces axially symmetric hollow bodies with nearly any contour. It is often used in combination with flow forming and shear spinning to manufacture a wide range of complex parts. This chapter describes the operating principles, stress states, and failure modes of each process along with typical applications and tooling requirements.
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in Classification and Description of Sheet Metal Forming Operations
> Sheet Metal Forming<subtitle>Fundamentals</subtitle>
Published: 01 August 2012
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in Forming of Titanium Plate, Sheet, Strip, and Tubing[1]
> Titanium: Physical Metallurgy, Processing, and Applications
Published: 01 January 2015
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Published: 01 December 2004
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Published: 01 June 1983
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2012
DOI: 10.31399/asm.tb.smff.t53400005
EISBN: 978-1-62708-316-4
... factor, m ( Eq 2.3 ), is used to model friction conditions. Recent studies in forming mechanics indicate that Eq 2.2 adequately represents the frictional shear stress in sheet metal forming. There are various methods of evaluating friction, that is, estimating the value of μ or m . Tests most...
Abstract
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.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2015
DOI: 10.31399/asm.tb.tpmpa.t54480243
EISBN: 978-1-62708-318-8
... to achieve a desired radius. Spinning and Shear Forming Spinning and shear forming are processes for shaping sheet metal into seamless hollow parts using pressure on a rotating workpiece. Spinning involves only minor thickness changes in the sheet metal, whereas shear forming is an extension...
Abstract
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.
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in Deformation and Fracture Mechanisms and Static Strength of Metals
> Mechanics and Mechanisms of Fracture: An Introduction
Published: 01 August 2005
(90 °C, or 195 °F), a radial fracture zone formed around the fibrous region, which formed first; also, the shear lip here is smaller. (c) No fibrous region formed in the specimen tested at −80 °C (−110 °F). Instead, fracture formed a radial zone that extends nearly to the specimen surface
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Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040067
EISBN: 978-1-62708-300-3
..., m, in the simple exponential law, σ ¯ = C ( ε ˙ ) m , used to express the strain-rate dependency of flow stress, discussed in Chapter 4 . Recent studies in forming mechanics indicate that Eq 7.2 adequately represents the frictional shear stress in forging, where...
Abstract
This chapter discusses the effect of friction and lubrication on forgings and forging operations. The discussion covers lubrication mechanisms, the use of friction laws, tooling and process parameters, and the lubrication requirements of specific materials and forging processes. The chapter also describes several test methods for evaluating lubricants and explains how to interpret associated test data.
Series: ASM Technical Books
Publisher: ASM International
Published: 30 November 2013
DOI: 10.31399/asm.tb.uhcf3.t53630071
EISBN: 978-1-62708-270-9
.... This type of fracture originates near the center of the section, with multiple cracks that join and spread outward until the 45° shear lip forms at the end of the fracture. Photo courtesy of Packer Engineering Associates, Inc. Fig. 3 Two identical steel bolts that had been given different heat...
Abstract
In order to understand how various types of single-load fractures are caused, one must understand the forces acting on the metals and also the characteristics of the metals themselves. All fractures are caused by stresses. Stress systems are best studied by examining free-body diagrams, which are simplified models of complex stress systems. Free-body diagrams of shafts in the pure types of loading (tension, torsion, and compression) are the simplest; they then can be related to more complex types of loading. This chapter discusses the principles of these simplest loading systems in ductile and brittle metals.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2012
DOI: 10.31399/asm.tb.smfpa.t53500001
EISBN: 978-1-62708-317-1
... material is sheared to a desired shape. In blanking, the removed piece of material is the product, whereas in piercing, the material that is removed is scrap, while the remaining part of the strip is the product ( Fig. 1.1 ). Blanking or piercing is used in almost all sheet-forming operations. The size...
Abstract
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.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 30 September 2023
DOI: 10.31399/asm.tb.stmflw.t59390064
EISBN: 978-1-62708-459-8
... at a specified shear rate. Departure from Newtonian behavior, or Non-Newtonian behavior, may take many forms: Dilatant fluids show an increase in viscosity with shear rate ( Fig. 5.3a ). This is typical of lubricants that are high in solid content. With the lubricant at rest, the solid particles...
Abstract
This chapter reviews the basic theory of lubrication in the context of metal forming applications. It discusses the rheological properties of fluids and their effect on fluid-film thickness at pressures, temperatures, and loading conditions typical of metal working processes. It describes the three lubrication regimes (boundary, mixed, and hydrodynamic) of a Stribeck curve and the forces that maintain surface separation. It also discusses mixed, elastohydrodynamic, plastohydrodynamic, and solid or semi-solid lubrication, the effects of starvation and frictional instabilities, and the role of elastic deflection and ultrasonic vibration.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2012
DOI: 10.31399/asm.tb.smff.t53400027
EISBN: 978-1-62708-316-4
... + ∂ w ˙ ∂ y ) Hence, for the most general three-dimensional deformation case, the complete set of strain rate components consists of three normal strain rate components and three independent shear strain rate components. In sheet metal forming, axisymmetric deformation problems...
Abstract
This chapter discusses the fundamentals of plastic deformation and the role of strain and strain rate in sheet metal forming processes. It describes the conditions associated with uniform deformation, the significance of engineering and true strain, the effect of volume constancy on the tensile response of isotropic and anisotropic materials, and how infinitesimal strains or strain rates are used to express and analyze instantaneous deformation and local stain. It also discusses the concept of principal strain and strain paths and explains how to determine, and when to use, equivalent strain and strain rate.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 30 November 2013
DOI: 10.31399/asm.tb.uhcf3.t53630101
EISBN: 978-1-62708-270-9
... a 45° angle. It is this slant fracture—frequently called a “shear lip”—that forms the cup-and-cone shape characteristic of many tensile fractures of ductile metal. This slant fracture is useful for study of many fractures, for it represents the end of the fracture process at that location. Tensile...
Abstract
Ductile fracture results from the application of an excessive stress to a metal that has the ability to deform permanently, or plastically, prior to fracture. Careful examination and knowledge of the metal, its thermal history, and its hardness are important in determining the correct nature of the fracture features. This chapter is a detailed account of the general characteristics and microstructural aspects of ductile fracture with suitable illustrations. It describes some of the complicating factors extraneous to the fracture itself.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040051
EISBN: 978-1-62708-300-3
..., this chapter discusses two major yield criteria that have been used extensively in the analysis of metal forming and forging. Tresca or shear stress criterion of yield or plastic flow von Mises or distortion energy criterion of yield or plastic flow 5.2.1 Tresca Yield Criterion The Tresca...
Abstract
This chapter covers the fundamentals of metal flow and the tools and techniques used to predict and control it. It begins by illustrating the local state of stress in a metal cylinder during upset forging and showing how stress components can be expressed in matrix form. It then explains how to determine the onset of yielding, which corresponds to the start of plastic deformation and the flow of metal within the workpiece. The chapter then goes on to present two important yield criteria, one based on shear stress (Tresca criterion), the other on distortion energy (von Mises criterion). It compares and contrasts the two methods and demonstrates their use as flow rules. It also explains how to calculate effective strain and strain rate and includes a brief discussion on the mechanical energy consumed during deformation.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2021
DOI: 10.31399/asm.tb.ciktmse.t56020001
EISBN: 978-1-62708-389-8
... Upon application of a shear stress on an edge dislocation, Fig. 4 shows that a step is formed eventually, along with the disappearance of the dislocation. This appears to imply that the dislocation density should decrease with deformation. In reality, plastic deformation results in increased...
Abstract
Alloying, heat treating, and work hardening are widely used to control material properties, and though they take different approaches, they all focus on imperfections of one type or other. This chapter provides readers with essential background on these material imperfections and their relevance in design and manufacturing. It begins with a review of compositional impurities, the physical arrangement of atoms in solid solution, and the factors that determine maximum solubility. It then describes different types of structural imperfections, including point, line, and planar defects, and how they respond to applied stresses and strains. The chapter makes extensive use of graphics to illustrate crystal lattice structures and related concepts such as vacancies and interstitial sites, ion migration, volume expansion, antisite defects, edge and screw dislocations, slip planes, twinning planes, and dislocation passage through precipitates. It also points out important structure-property correlations.
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Published: 30 November 2013
Fig. 1 Schematic sketch of microstructural changes in crystal structure due to repetitive shearing forces. Spheres represent atoms, and lines represent attractive and repulsive interatomic forces. An edge dislocation, represented by the inverted T-shaped symbol, is an imperfection
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Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2012
DOI: 10.31399/asm.tb.smff.t53400089
EISBN: 978-1-62708-316-4
... interface create hydrodynamic conditions. Coulomb, Tresca, and Modified Shear Friction Models Two friction models are commonly used to describe the frictional condition in metal forming processes: Coulomb’s friction model ( Eq 7.1 ) and the shear friction model ( Eq 7.2 ). Both models quantify...
Abstract
This chapter discusses the factors that must be considered when selecting a lubricant for sheet metal forming operations. It begins with a review of lubrication regimes and friction models. It then describes the selection and use of sheet metal forming lubricants, explaining how they are applied and removed and how their pressure and temperature ranges can be extended by performance enhancing additives. The chapter also explains how sheet metal forming lubricants are evaluated in the laboratory as well as on the production floor and how tribological tests are conducted to simulate stamping, deep drawing, ironing, and blanking operations.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040017
EISBN: 978-1-62708-300-3
... 3.1 Introduction The purpose of applying the plasticity theory in metal forming is to investigate the mechanics of plastic deformation in metal forming processes. Such investigation allows the analysis and prediction of (a) metal flow (velocities, strain rates, and strains), (b) temperatures...
Abstract
This chapter discusses the role of plastic deformation in forging and the effect of strain and strain rate on metal flow. It demonstrates the use of stress tensors and shows how metal flow can be represented qualitatively by the displacement of volume elements and quantitatively by the distribution of velocity components and strain rates. It describes the conditions associated with homogeneous deformation in a frictionless upset forging and explains how they can also be obtained using engineering and true stress-strain curves.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.t53740163
EISBN: 978-1-62708-308-9
... at room temperature and must therefore be formed at elevated temperatures. Preparation of Plate and Flat Sheet Prior to forming, the plate or sheet must be cut to the proper size. This can be done by a number of methods—the most prevalent being sawing, shearing, and oxyfuel gas cutting. Because...
Abstract
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.
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