Sheet Metal Forming—Processes and Applications
Copyright © 2012 ASM
International
®
T. Altan and A.E. Tekkaya, editors
All rights reserved
www.asminternational.org
Preface
vii
In
sheet metal forming, a sheet blank that has a simple shape is plastically formed
between tools (or dies) to obtain a part with relatively complex geometry with desired
tolerances and properties. Sheet metal forming processes usually produce little scrap
and generate the final part geometry in a very short time, usually in one stroke or a few
strokes of a press. As a result, sheet forming offers potential savings
in energy and
material, especially in medium and large production quantities, where tool costs can be
easily amortized.
The ever-increasing costs
of material, energy and manpower require that sheet metal
forming processes and tooling be designed and developed with minimum amount of
trial and error with shortest possible lead times. Therefore, to remain competitive, the
cost-effective application of
computer-aided technologies, i.e. CAD, CAM, CAE, and
especially finite element analysis (FEA), computer-based simulation is an absolute
necessity. Thus, process modeling using FEA has been discussed in all appropriate
chapters.
The practical and efficient use of these technologies require
s a
thorough knowledge
of the principle variables of the sheet metal forming processes and their interactions.
These variables include:
1. the flow behavior and formability of the formed sheet material under processing
conditions;
2. die geometry, materials and coatings;
3.
friction and lubrication;
4. the mechanics of deformation, i.e. strains, stresses and forces;
5. characteristics of the sheet metal forming
presses and tooling;
6. geometry, tolerances, surface finish and mechanical properties of the formed
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