Material forming processes: simulation, drawing, hydroforming and additive manufacturing
Saved in:
| Main Authors: | , |
|---|---|
| Format: | Book |
| Language: | English |
| Published: |
London
ISTE
2016
Hoboken, NJ Wiley 2016 |
| Series: | Mathematical and mechanical engineering set
volume 1 |
| Subjects: | |
| Online Access: | Inhaltsverzeichnis Klappentext |
| Physical Description: | xii, 254 Seiten Illustrationen |
| ISBN: | 9781848219472 1848219474 |
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MARC
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Record in the Search Index
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| adam_text | Contents
9
Preface.............................................................. xi
Chapter 1. Forming Processes ..................................... 1
1.1. Introduction ............................................... 1
1.2. Different processes ........................................ 1
1.2.1. Smelting................................................ 2
1.2.2. Machining............................................... 3
1.2.3. Powder metallurgy....................................... 5
1.3. Hot and cold forming........................................ 6
1.3.1. Influence of the static parameters...................... 9
1.3.2. Hydroforming........................................... 12
1.3.3. The limitations of the process......................... 13
1.3.4. Deep drawing........................................... 14
1.4. Experimental characterization.............................. 14
1.5. Forming criteria........................................... 16
1.5.1. Influence of the structure of sheet metal.............. 18
1.5.2. Physical strain mechanisms............................. 20
1.5.3. Different criteria..................................... 21
Chapter 2. Contact and Large Deformation Mechanics .... 23
2.1. Introduction .............................................. 23
2.2. Large transformation kinematics............................ 23
2.2.1. Kinematics of the problem in spatial coordinates .... 24
2.3. Transformation gradient.................................... 25
2.4. Strain measurements ....................................... 26
2.4.1. Polar decomposition of F................................ 26
vi Material Forming Processes
2.4.2. Strain rate tensor....................................... 27
2.4.3. Canonical decomposition of F........................... 28
2.4.4. Kinematics of the problem in convective coordinates .... 28
2.4.5. Transformation tensor.................................... 29
2.4.6. Strain rate measures..................................... 32
2.4.7. Strain tensor ......................................... 35
2.5. Constitutive relations...................................... 36
2.5.1. Large elastoplastic transformations...................... 38
2.5.2. Kinematic decomposition of the transformation.......... 41
2.6. Incremental behavioral problem ............................. 42
2.6.1. Stress incrementation.................................... 42
2.6.2. Strain incrementation.................................... 44
2.6.3. Solution of the behavior problem....................... 46
2.7. Definition of the P.V.W. in major transformations......... 49
2.7. L Equilibrium equations.................................. 49
2.7.2. Definition of the P.V.W.................................. 50
2.7.3. Incremental formulation ................................. 51
2.8. Contact kinematics ......................................... 52
2.8.1. Definition of the problem and notations ............... 52
2.8.2. Contact formulation...................................... 53
2.8.3. Formulation of the friction problem...................... 53
2.8.4. Friction laws............................................ 54
2.8.5. Coulomb’s law............................................ 54
2.8.6. Tresca’s law............................................ 55
Chapter 3- Stamping ................................................. 57
3.1. Introduction ............................................... 57
3.2. Forming limit curve......................................... 59
3.3. Stamping modeling: incremental problem .................... 60
3.3.1. Modeling of sheet metal ................................. 61
3.3.2. Spatial discretization: finite elements method........... 62
3.3.3. Choice of sheet metal and finite element approximation . . 63
3.4. Modeling tools.............................................. 64
3.4.1. Tool surface meshing into simple geometry elements .... 64
3.4.2. Analytical representation of tools....................... 65
3.4.3. Bezier patches......................................... 65
3.5. Stamping numerical processing.............................. 72
3.5.1. Problem statement........................................ 73
3.5.2. The augmented Lagrangian method.......................... 75
3.6. Numerical simulations .................................... 79
3.6.1. Sollac test ............................................. 81
Contents vii
Chapter 4. Hydroforming .......................................... 83
4.1. Introduction ................................................ 83
4.2. Hydroforming................................................. 85
4.2.1. Tube hydroforming........................................ 85
4.2.2. Sheet metal hydroforming................................. 86
4.3. Plastic instabilities in hydroforming..................... 87
4.3.1. Tube buckling............................................ 88
4.3.2. Wrinkling................................................ 90
4.3.3. Necking.................................................. 91
4.3.4. Springback............................................... 92
4.4. Forming limit curve........................................ 92
4.5. Material characterization for hydroforming................ 94
4.5.1. Tensile testing.......................................... 95
4.5.2. Bulge testing............................................ 95
4.6. Analytical modeling of a inflation test................... 97
4.6.1. Hill48 criterion in planar stresses................... 97
4.7. Numerical simulation........................................ 100
4.8. Mechanical characteristic of tube behavior.................. 101
Chapter 5. Additive Manufacturing................................... 105
5.1. Introduction ............................................... 105
5.2. RP and stratoconception .................................. 107
5.3. Additive manufacturing definitions.......................... 109
5.4. Principle................................................... 113
5.4.1. Principle of powder bed laser sintering/melting....... 114
5.4.2. Principle of laser sintering/melting by projecting
powder......................................................... 116
5.5. Additive manufacturing in the IT-based development
process.......................................................... 117
5.5.1. Concept “from the object to the object”............... 117
5.5.2. Key element of the IT development process............... 118
Chapter 6. Optimization and Reliability in Forming.................. 121
6.1. Introduction ............................................... 121
6.2. Different approaches to optimization processes ............. 122
6.2.1. Limitations of the deterministic approaches ............ 124
6.3. Characterization of forming processes by objective
functions........................................................ 125
6.4. Deterministic and probabilistic optimization of a
T-shaped tube.................................................... 126
6.4.1. Problem description..................................... 126
viij Material Forming Processes
6.4.2. Choice of the objective function and definition
of the stresses................................................... 127
6.4.3. Choice of the uncertain parameters........................ 128
6.4.4. Choice of the objective function and the stresses......... 130
6.4.5. Deterministic formulation of the optimization problem ... 132
6.4.6. Probabilistic formulation of the optimization problem .... 133
6.4.7. Optima sensitivity to uncertainties........................ 140
6.5. Deterministic and optimization-based reliability of a tube
with two expansion regions........................................ 142
6.5.1. Problem description...................................... 142
6.5.2. Deterministic and reliabilist formulation of the
optimization problem............................................ 147
6.6. Optimization-based reliability of circular sheet metal
hydroforming........................................................ 150
6.6.1. Problem description........................................ 150
6.6.2. Construction of the objective function and of the
stresses.......................................................... 151
6.6.3. Effects diagram............................................ 151
6.6.4. Deterministic solution of the optimization problem........ 155
6.6.5. Reliabilist solution of the optimization problem............157
6.6.6. Effect of uncertainties on the optimal variables ......... 159
6.7. Deterministic and robust optimization of a square plate.......160
6.7.1. Robust resolution of the optimization problem.............. 166
6.8. Optimization of thin sheet metal . . .........................168
Chapter 7. Application of Metamodels to Hydroforming .... 171
7.1. Introduction ................................................. 171
7.2. Sources of uncertainty in forming............................. 172
7.3. Failure criteria.............................................. 173
7.3.1. Failure criteria for necking............................... 174
7.3.2. Failure criteria for wrinkling............................. 174
7.4. Evaluation strategy of the probability of failure ........... 175
7.4.1. Finite element model and choice of uncertainty
parameters........................................................ 176
7.4.2. Identification of failure modes and definition of
boundary states.................................................. 180
7.4.3. Identification of elements and critical areas............. 181
7.5. Critical strains probabilistic characterization............... 185
7.5.1. Choice of numerical experimental design.................... 186
7.5.2. Construction of metamodels................................. 186
7.5.3. Validation and statistical analysis of metamodels ...... 187
Contents ix
7.5.4. Fitting of distributions.............................. 187
7.6. Necking and wrinkling probabilistic study................ 193
7.7. Effects of the correlations on the probability of failure ..... 196
7.7.1. Spatial estimation of the probability of failures..... 197
Chapter 8. Parameters Identification in Metal Forming .... 199
8.1. Introduction ............................................. 199
8.2. Identification methods.................................. . 199
8.2.1. Validation test . .....................................200
8.3. Welded tube hydroforming.................................. 203
8.3.1. Thin sheet metal hydroforming .........................205
Appendices........................................................ 213
Appendix 1. Optimization in Mechanics ..............................215
Appendix 2. Reliability in Mechanics ...............................223
Appendix 3. Metamodels .............................................233
Bibliography .......................................................243
Index
253
MATHEMATICAL AND MECHANICAL ENGINEERING SET
Coordinated by Abdelkhalak Ei Hami
Manufacturing industries strive to improve the quality and
reliability of their products, while simultaneously reducing
production costs. To do this, modernized work tools must be
produced; this will enable a reduction in the duration of the product
development cycle, optimization of product development
procedures, and ultimately improvement in the productivity of
design and manufacturing phases.
Numerical simulations of forming processes are used to this end,
and in this book various methods and models for forming
processes (including stamping, hydroforming and additive
manufacturing) are presented. The theoretical and numerical
advances of these processes involving large deformation
mechanics on the basis of large transformations are explored, in
addition to the various techniques for optimization and calculation
of reliability.
The advances and techniques within this book will be of interest
to professional engineers in the automotive, aerospace, defence
and other industries, as well as graduates and undergraduates in
these fields.
Bouchaib Radi is Full Professor of FST at Hassan Premier
University, Settat, Morocco. His research interests include forming,
optimization and reliability.
Abdelkhalak El Hami is Full Professor at INSA Rouen, University
of Normandy, France. His research interests include optimization,
reliability and structural dynamics.
|
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| author | Radi, Bouchaib El Hami, Abdelkhalak |
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| discipline | Werkstoffwissenschaften / Fertigungstechnik |
| format | Book |
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| spelling | Radi, Bouchaib Verfasser (DE-588)1125967986 aut Material forming processes simulation, drawing, hydroforming and additive manufacturing Bouchaib Radi, Abdelkhalak El Hami London ISTE 2016 Hoboken, NJ Wiley 2016 xii, 254 Seiten Illustrationen txt rdacontent n rdamedia nc rdacarrier Mathematical and mechanical engineering set volume 1 Umformen (DE-588)4061585-6 gnd rswk-swf Fertigungstechnik (DE-588)4329079-6 gnd rswk-swf Umformen (DE-588)4061585-6 s DE-604 Fertigungstechnik (DE-588)4329079-6 s El Hami, Abdelkhalak Verfasser (DE-588)107586254X aut Mathematical and mechanical engineering set volume 1 (DE-604)BV044235763 1 Digitalisierung UB Bayreuth - ADAM Catalogue Enrichment application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=029200895&sequence=000003&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis Digitalisierung UB Bayreuth - ADAM Catalogue Enrichment application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=029200895&sequence=000004&line_number=0002&func_code=DB_RECORDS&service_type=MEDIA Klappentext |
| spellingShingle | Radi, Bouchaib El Hami, Abdelkhalak Material forming processes simulation, drawing, hydroforming and additive manufacturing Mathematical and mechanical engineering set Umformen (DE-588)4061585-6 gnd Fertigungstechnik (DE-588)4329079-6 gnd |
| subject_GND | (DE-588)4061585-6 (DE-588)4329079-6 |
| title | Material forming processes simulation, drawing, hydroforming and additive manufacturing |
| title_auth | Material forming processes simulation, drawing, hydroforming and additive manufacturing |
| title_exact_search | Material forming processes simulation, drawing, hydroforming and additive manufacturing |
| title_full | Material forming processes simulation, drawing, hydroforming and additive manufacturing Bouchaib Radi, Abdelkhalak El Hami |
| title_fullStr | Material forming processes simulation, drawing, hydroforming and additive manufacturing Bouchaib Radi, Abdelkhalak El Hami |
| title_full_unstemmed | Material forming processes simulation, drawing, hydroforming and additive manufacturing Bouchaib Radi, Abdelkhalak El Hami |
| title_short | Material forming processes |
| title_sort | material forming processes simulation drawing hydroforming and additive manufacturing |
| title_sub | simulation, drawing, hydroforming and additive manufacturing |
| topic | Umformen (DE-588)4061585-6 gnd Fertigungstechnik (DE-588)4329079-6 gnd |
| topic_facet | Umformen Fertigungstechnik |
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