This comprehensive reference on sheet metal forming and fabrication provides state-of-the-art reference information for product and production engineers. Coverage addresses all methods of sheet metal fabrication technologies, selection of equipment and die materials, specification of forming practices for specific alloys, and new techniques for process design and control. This Volume provides you with practical reference information on the basic processes of press forming, drawing, bending, spinning, shearing, blanking, and piercing of sheet with additional coverage on forming with bar, tube, wire, shapes, or long parts. New content areas include:Expanded coverage on computer-based methods for process simulation and control Advanced high-strength steels (AHSS) forming and material developments Expanded coverage on the evaluation and mitigation of springback and the troubleshooting of formability problems Rapid prototyping and die-less flexible manufacturing techniques such as thermal forming and peen forming Updates on cold-work powder metallurgy tool steels and tool coatings Updates and addition of practical reference information on basic operations of bending, press forming, and press brake forming Application of tailor weld blanks New process related developments in superplastic forming and conventional forming of aluminum, titanium, nickel, magnesium, and refractory alloys Recent process modifications in hydroforming and high-velocity metal forming Contents Include: Introduction to Forming Processes Shearing, Cutting, Blanking, and Piercing Equipment for Forming of Sheet Metal Tooling and Fabrication for Forming Sheet, Strip, and Plate Forming Processes for Sheet, Strip, and Plate Forming of Bar, Tube, and Wire Sheet Forming of Specific Ferrous and Nonferrous Metals Formability Analysis Process Design and Modeling for Sheet Forming Reference Information Index

This Handbook provides insight into the integration of modeling for simulation of manufacturing processing. The metals industry is moving toward an integrated computational materials engineering approach (ICME). This provides engineers with accurate predictions of material and process behavior to avoid or reduce costly trial-by-error and prototyping methods of development. The table of contents illustrates the depth and breadth of the processes addressed. This area of engineering has been advancing rapidly, accruing the benefits of reduced manufacturing costs and improved component design. This book serves as a reference to these developments. Condensed Table of Contents:Input Data for Simulations -Flow Stress Measurements, Thermophysical Properties of Solids and Liquids, Thermophyscial Properties (and Their Determination) for Solidification Models Grain Boundary Energy and Mobility, Crystallographic Texture, 3D Microstructure Representation, Solid Models for Simulation Simulation of Deformation Processes - FEM, Slab, and Upper Bound Methods for Deformation Processes, Forging,Bending and Forming Processes, Simulation and Modeling of Powder Metallurgy Processes, Press and Sinter P/M, Modeling of HIP, M/P Injection Molding, Compaction Modeling, Process Modeling of Higher-Density Consolidation Simulation of Solidification - Computational Analysis of the VAR and ESR Processes, Porosity during Solidification, Simulation of Casting and Solidification Processes, Cellular-automata Models for Solidification Processes, Solidification Heat Transfer Simulations, Simulation of Fluid Flow and Heat/Mass Transfer Modeling of Solidification Microstructures, Transport Phenomena for during Solidification Processes, Microstructure and texture formation during solidification Simulation of Machining Processes - Shearing and Blanking, Orthogonal cutting/chip formation (Includes Simulation of machining residual stresses) Machining Distortion in Nickel-Base Disks Simulation of Joining Operations - Integrated Weld Modeling, Simulation of Joining Operations, Rotational Welding, FSW, Diffusion Bonding, Additive Manufacturing Processes Simulation of Heating and Heat Treatment - Computerized Properties Prediction and Technology Planning in Heat Treatment of Steels, Heating and Heat-Flow Simulation, Quenching, Residual Stress Formation, and Quench Cracking, Stress-Relief, Induction Heating, Surface Treatments, Shot-peening Processes Induction Heat Treatment, Diffusion Coating Techniques Simulation of Phase Diagrams and Transformations - Application of Thermodynamic and Material Property Modeling to Process Simulation of Industrial Alloys, Commercial Alloy Phase Diagrams and Industrial Applications,Quantitative Prediction of Transformation Hardening in Steels Integration of Modeling and Simulation in Design - Design Optimization Methodologies, Propagation of Errors and Managing Uncertainty Glossary Index This Volume joins the companion, Volume 22A, Fundamentals of Modeling for Metals Processing to provide a complete authoritative reference for the modeling practitioner, or the student or engineer beginning their quest for information.

This Handbook provides an overview of the development of models of metallic materials and how the materials are affected by processing. This knowledge is central to understanding of the behavior of existing alloys and the development of new materials that affect nearly every manufacturing industry. Background on fundamental modeling methods provides the user with a solid foundation of the underlying physics that support the mechanistic method of many industrial simulation software packages. The phenomenological method is given equal coverage. The substantial efforts of the past 25 years to develop and implement computer-based models to simulate manufacturing processes, the evolution of microstructures, and the effects on the mechanical properties within component materials are detailed. The rate of change within this area of engineering has continued to increase with increasing industrial benefits from the use of such engineering tools, and the reduced cost and increased speed of computing systems required to perform the extensive model calculations. This book serves as a reference to these developments and the governing principles on which they are based. Leading experts from ten countries have contributed to this effort to provide a comprehensive reference for the modeling practitioner as well as those needing to learn modeling methods. This Volume will be joined by a companion, Volume 22B, Metals Process Simulation, that will provide details on integrating these models into software tools to allow simulation of manufacturing processes.

If you design, evaluate, or produce metal parts, this is an indispensable reference on the principles and practices of workability evaluation and process design. Workability is a complex technological concept that is related to both material and process characteristics, and this book describes the underlying concepts and practical methods for effective design, evaluation, and optimization of bulk working operations such as forging, rolling, and extrusion. The Handbook of Workability and Process Design includes updated content from a previous ASTM publication (Workability Testing Techniques, 1984) as well as substantial new coverage in the areas of process design, numerical simulation, and computer-based modeling of testing and processing conditions. Contents: Introduction: Overview of workability and process design; Bulk working behavior of metals; Evolution of microstructure during bulk working; Workability testing techniques: Bulk workability testing; Cold upset testing; Hot compression testing; Hot tension testing; Torsion testing to assess bulk workability; Hot working simulation by hot torsion testing; Thermomechanical testing; Process design and workability: Design for deformation processes; Workability theory and application in bulk forming processes; Workability in forging; Forging process design; Modeling techniques in forging process design; Data acquisitions and control; Rolling; Workability and process design in rolling; Drawing; Extrusion; Workability and process design in extrusion and wire drawing; Multidisciplinary process design and optimization: Computer aided and multidisciplinary optimization of forging processes; Microstructure driven computer-aided process optimization; Process design of gas turbine engine components using process optimization software; Computer-aided optimization to improve process engineering productivity for complex die and preform design, and process control; Index

Written by experts in the field, this book provides an excellent overview of the range of applications of induction heating. It also describes methods by which conventional as well as special heating jobs can be designed around the capabilities of the process. The book discusses the theory of induction heating tuning of induction heating circuits and load matching and summarizes major equipment considerations in designing induction heading systems. Design procedures are thoroughly covered for heat treating, through heating, induction melting, pipe welding, and induction brazing and soldering operations. The discussion on fundamentals of process control deals with thermocouples, radiation detectors, proportional controllers, heating of steel slabs, surface hardening, vacuum induction melting, electric demand control, electromagnetic sorting, colorimetic evaluation, and process simulation. Information is provided on basic coil designs, common design modifications, specialty coils, and coil fabrication, as well as flux concentrators, shields, and susceptors. The last three chapters deal, respectively, with materials handling, special applications, and economics.The book is completed with cost elements for induction heating and typical cost comparisons. Liberally illustrated and thoroughly indexed, the book is intended for those who do not necessarily have a background in electrical engineering or process heating. It serves well as an introductory text and as a reference for practical engineers.