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Title: Practice of Process Modeling of Metal Forming in Manufacturing Environment

Abstract

For the last two decades, applications of finite element analysis have tremendously reshaped the metal forming and manufacturing industries. Today, this method is commonly employed as an effective tool to help engineers (1) in conceptual development or virtual prototyping phase precisely predict the behavior of the part to be formed so that the tools can be correctly designed and (2) in product improvement phase correctly and effectively identify the root causes of product defects and provide solutions. These demands, however, have not been well satisfied, mostly because of the difficulties in the complex nonlinearities and boundary conditions in metal forming, implementation of accurate and sophisticated solution methodologies and an accurate material response through appropriate constitutive equations. Approximations and limitations of the programs may not result in the desirable accuracy sought from the simulation and therefore may lead the engineers in a dilemma in interpretation of simulation results. This paper presents and discusses a number of commonly met issues, including prediction of workpiece fracture and influence of material characteristics and friction conditions on such fracture occurrence, in process modeling of a cold extrusion forming method with a hope that these issues can be solved more successfully when the finite element programsmore » have been further advanced.« less

Authors:
 [1]
  1. Timken Company, Canton, Ohio 44706 (United States)
Publication Date:
OSTI Identifier:
21061783
Resource Type:
Journal Article
Resource Relation:
Journal Name: AIP Conference Proceedings; Journal Volume: 908; Journal Issue: 1; Conference: NUMIFORM 2007: 9. international conference on numerical methods in industrial forming processes, Porto (Portugal), 17-21 Jun 2007; Other Information: DOI: 10.1063/1.2740936; (c) 2007 American Institute of Physics; Country of input: International Atomic Energy Agency (IAEA)
Country of Publication:
United States
Language:
English
Subject:
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSICS; ACCURACY; ALLOYS; APPROXIMATIONS; BOUNDARY CONDITIONS; EXTRUSION; FINITE ELEMENT METHOD; FRACTURES; FRICTION; MANUFACTURING; NONLINEAR PROBLEMS; TOOLS

Citation Formats

He Ming. Practice of Process Modeling of Metal Forming in Manufacturing Environment. United States: N. p., 2007. Web. doi:10.1063/1.2740936.
He Ming. Practice of Process Modeling of Metal Forming in Manufacturing Environment. United States. doi:10.1063/1.2740936.
He Ming. Thu . "Practice of Process Modeling of Metal Forming in Manufacturing Environment". United States. doi:10.1063/1.2740936.
@article{osti_21061783,
title = {Practice of Process Modeling of Metal Forming in Manufacturing Environment},
author = {He Ming},
abstractNote = {For the last two decades, applications of finite element analysis have tremendously reshaped the metal forming and manufacturing industries. Today, this method is commonly employed as an effective tool to help engineers (1) in conceptual development or virtual prototyping phase precisely predict the behavior of the part to be formed so that the tools can be correctly designed and (2) in product improvement phase correctly and effectively identify the root causes of product defects and provide solutions. These demands, however, have not been well satisfied, mostly because of the difficulties in the complex nonlinearities and boundary conditions in metal forming, implementation of accurate and sophisticated solution methodologies and an accurate material response through appropriate constitutive equations. Approximations and limitations of the programs may not result in the desirable accuracy sought from the simulation and therefore may lead the engineers in a dilemma in interpretation of simulation results. This paper presents and discusses a number of commonly met issues, including prediction of workpiece fracture and influence of material characteristics and friction conditions on such fracture occurrence, in process modeling of a cold extrusion forming method with a hope that these issues can be solved more successfully when the finite element programs have been further advanced.},
doi = {10.1063/1.2740936},
journal = {AIP Conference Proceedings},
number = 1,
volume = 908,
place = {United States},
year = {Thu May 17 00:00:00 EDT 2007},
month = {Thu May 17 00:00:00 EDT 2007}
}