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2015 | Book

Deformation of Metals Read chapter Read first chapter

Electrically Assisted Forming

Modeling and Control

Authors: Wesley A. Salandro, Joshua J. Jones, Cristina Bunget, Laine Mears, John T. Roth

Publisher: Springer International Publishing

Book Series : Springer Series in Advanced Manufacturing

Part of: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik"

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About this book

Maximizing reader insights into the latest research findings and applications of Electrically-Assisted Forming (EAF) – whereby metals are formed under an electric current field – this book explains how such a process produces immediate improved formability of metals beyond the extent of thermal softening, and allows metals to be formed to greater elongation with lower mechanical energy as well as allowing for lightweight brittle metals such as magnesium and titanium to be formed without external heating or annealing, enabling the more effective use of these lightweight metals in design.

Including case studies that illustrate and support the theoretical content and real-world applications of the techniques discussed, this book also serves to enrich readers understanding of the underlying theories that influence electro-plastic behaviour.

The authors have extensive experience in studying Electrically-Assisted Forming and have written extensively with publications including experimental works, technical briefs, conference proceedings, journal articles, and analytical models.

Table of Contents

Frontmatter
Chapter 1. Deformation of Metals
Abstract
Deformation of metals is one of the key manufacturing processes for adding value in secondary operations. Deformation as a process evolved soon after metal refinement in ancient times to shape tools and other functional parts. With the dawn of the second Industrial Age, the availability of localized power sources allowed for the development of more standardized automated processes for metal deformation, such as forging, stamping, drawing, and extrusion. These processes gave rise to high-value, standardized components for construction, vehicles, and consumer goods.
Wesley A. Salandro, Joshua J. Jones, Cristina Bunget, Laine Mears, John T. Roth
Chapter 2. Introduction to Electrically Assisted Forming
Abstract
Electrically assisted forming (EAF) is a recently introduced metal-forming technique capable of enhancing a metal’s formability during deformation and reducing springback after deformation.
Wesley A. Salandro, Joshua J. Jones, Cristina Bunget, Laine Mears, John T. Roth
Chapter 3. The Effect of Electric Current on Metals
Abstract
This chapter describes the fundamentals behind electroplasticity in metals. Specifically, it focuses on electrical current flow, previous electroplastic theories, and an overall explanation of the electroplastic effect on metals. This overall theory will be supported with experimental results, and electroplastic conclusions will be drawn at the end of the chapter.
Wesley A. Salandro, Joshua J. Jones, Cristina Bunget, Laine Mears, John T. Roth
Chapter 4. Macroscale Modeling of the Electroplastic Effect
Abstract
For successful implementation of EAF in manufacturing industries, one area that needs to be addressed is the predictability or material response at a bulk level. This chapter introduces the modeling strategy for the electroplastic effect at the macroscale, which are used for compressive modeling (Chap. 5) and tensile modeling (Chap. 6). For macro-level modeling of EAF in Chaps. 5 and 6, the models use a coupled thermo-mechanical approach based on energy and displacement continuity. Additional laws utilized in Chaps. 5 and 6 include: the first law of thermodynamics, Joule’s first law for heat generation, Fourier’s law for conduction, and Newton’s law of cooling.
Wesley A. Salandro, Joshua J. Jones, Cristina Bunget, Laine Mears, John T. Roth
Chapter 5. Compressive Electrically Assisted Forming Model
Abstract
The overall goal of this chapter is to develop a model for an electrically assisted forging process and then use this model to highlight specific sensitivities and relationships within the EAF process. A modeling strategy will be defined, based on existing conventional forging equations. These equations will then be modified to account for the electroplastic effect in an EAF process.
Wesley A. Salandro, Joshua J. Jones, Cristina Bunget, Laine Mears, John T. Roth
Chapter 6. Tensile Electroforming Model
Abstract
This chapter contains modeling work for sheet metal subject to an applied direct electrical current in uniaxial tension. The modeling is divided into a thermal and mechanical approach which is combined to a thermo-mechanical model to predict the deformation behavior during EAF.
Wesley A. Salandro, Joshua J. Jones, Cristina Bunget, Laine Mears, John T. Roth
Chapter 7. Control of Electrically Assisted Forming
Abstract
In this chapter, several control approaches are described for forming a metal under an electrical current field. In addition, the approaches are demonstrated and potential applications for these control schemes are discussed. The specific examples where closed-loop control is used to determine the process output are for constant force forming, constant stress forming, and constant current density (CCD) forming. Last, the feasibility toward model-based control (MBC) is discussed for the models developed in Chaps. 4–6.
Wesley A. Salandro, Joshua J. Jones, Cristina Bunget, Laine Mears, John T. Roth
Chapter 8. Microstructure and Phase Effects on EAF
Abstract
This chapter evaluates the microstructure and its impact on EAF. This chapter is divided into three sections where Sect. 8.1 discusses the impact that different starting grain sizes have on the thermal and mechanical profiles of EAF in compression. Section 8.2 evaluates differences in starting dislocation density (from specimen pre-working) and how they impact mechanical EAF profiles. Section 8.3 provides analysis for post-formed microstructure of tensile sheet specimens using statistical methods. To illustrate these concepts, the chapter contains experimental testing and analysis.
Wesley A. Salandro, Joshua J. Jones, Cristina Bunget, Laine Mears, John T. Roth
Chapter 9. Tribological and Contact Area Effects
Abstract
In order for the electroplastic effect to take place, the applied electricity must be able to flow from the dies and through the workpiece. Because of this, the interfaces between the dies/workpiece are critical.
Wesley A. Salandro, Joshua J. Jones, Cristina Bunget, Laine Mears, John T. Roth
Chapter 10. Design of an Electrically Assisted Manufacturing Process
Abstract
In previous chapters, we have explored the underlying physics behind electrically assisted manufacturing (EAM), how to model the phenomenon, and its effect on deformation process forces, power, and resultant microstructure. In this chapter, we aim to explore the feasibility of implementing EAM on a commercial scale, primarily specific design requirements, cost, and sustainability impact on the manufacturing system as a whole.
Wesley A. Salandro, Joshua J. Jones, Cristina Bunget, Laine Mears, John T. Roth
Chapter 11. Applications of Electrically Assisted Manufacturing
Abstract
Within this book, a modeling strategy for the EAF technique is explained for both compression and tension. Both strategies separate the thermal softening effects from the direct electrical effects and thus produce temperature and force profiles for their respective processes. However, in the real world, manufacturing processes are rarely exclusively compression or tension. Therefore, within this chapter, manufacturing processes that can be applicable to EAF will be explained. These include bending, stretch forming, machining, friction stir welding, and miscellaneous other EAF-industrialization research by researchers other than the authors. In addition, this chapter will include experimental EAF findings for compression, tension, channel formation, springback, and various types of forming.
Wesley A. Salandro, Joshua J. Jones, Cristina Bunget, Laine Mears, John T. Roth
Backmatter
Metadata
Title
Electrically Assisted Forming
Authors
Wesley A. Salandro
Joshua J. Jones
Cristina Bunget
Laine Mears
John T. Roth
Copyright Year
2015
Electronic ISBN
978-3-319-08879-2
Print ISBN
978-3-319-08878-5
DOI
https://doi.org/10.1007/978-3-319-08879-2

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