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2013 | Book

Theories, Methods and Numerical Technology of Sheet Metal Cold and Hot Forming

Analysis, Simulation and Engineering Applications

Authors: Ping Hu, Ning Ma, Li-zhong Liu, Yi-guo Zhu

Publisher: Springer London

Book Series : Springer Series in Advanced Manufacturing


About this book

Over the last 15 years, the application of innovative steel concepts in the automotive industry has increased steadily. Numerical simulation technology of hot forming of high-strength steel allows engineers to modify the formability of hot forming steel metals and to optimize die design schemes. Theories, Methods and Numerical Technology of Sheet Metal Cold and Hot Forming focuses on hot and cold forming theories, numerical methods, relative simulation and experiment techniques for high-strength steel forming and die design in the automobile industry.

Theories, Methods and Numerical Technology of Sheet Metal Cold and Hot Forming introduces the general theories of cold forming, then expands upon advanced hot forming theories and simulation methods, including:

the forming process,
constitutive equations,
hot boundary constraint treatment, and
hot forming equipment and experiments.

Various calculation methods of cold and hot forming, based on the authors’ experience in commercial CAE software for sheet metal forming, are provided, as well as a discussion of key issues, such as hot formability with quenching process, die design and cooling channel design in die, and formability experiments.

Theories, Methods and Numerical Technology of Sheet Metal Cold and Hot Forming will enable readers to develop an advanced knowledge of hot forming, as well as to apply hot forming theories, calculation methods and key techniques to direct their die design. It is therefore a useful reference for students and researchers, as well as automotive engineers.

Table of Contents

Chapter 1. The Introduction of Sheet Metal Forming Technology
Metal pressure processing, also known as metal plastic working, is a kind of manufacturing method, which makes use of metal plastic deformation caused under external force to obtain raw materials, blanks, or components with certain shape, size, and mechanical property.
Ping Hu, Ning Ma, Li-zhong Liu, Yi-Guo Zhu
Chapter 2. The Basics and Equipments of Sheet Metal Forming
As one of the advanced metal processing methods, cold stamping mold is mainly used in sheet metal processing, so it is also called sheet metal stamping. It is a pressure processing method that puts pressure on the sheets or profiles at room temperature by the use of stamping mold to produce plastic deformation or separation and then to obtain parts with certain shape, size, and performance.
Ping Hu, Ning Ma, Li-zhong Liu, Yi-Guo Zhu
Chapter 3. Hot Forming Process
In the direct hot forming process, a blank is heated up in a furnace, transferred to the press and subsequently formed and quenched in the closed mold [1] (Fig. 3.1). First the sheet is uncoiled and cut according to the shape of the product, then the blank is transferred to a continuous furnace, in which it is heated and fully austenitized. Thus the product is formed and quenched after the blank is transferred to the hot forming mold with cooling system. Afterwards the product is trimmed by laser and finished through other follow-up process.
Ping Hu, Ning Ma, Li-zhong Liu, Yi-Guo Zhu
Chapter 4. The Basic Mechanical Properties and Experimental Verification for Hot Forming Steel
Metal is the most important material in modern industry, widely used in agriculture, industry, national defense industry, and other departments. Since the selection of materials for most mechanical equipments is based on its mechanical performance, the mechanical properties of metals should be first known. This section will focus on the plasticity and deformation resistance of metal materials and their influencing factors.
Ping Hu, Ning Ma, Li-zhong Liu, Yi-Guo Zhu
Chapter 5. The Basic Theory and Constitutive Equation Constitutive Equation of High-Strength Steel High-strength steel for Hot Forming hot Forming
The first part of this book briefly describes the basic principle of high-strength steel for hot stamping technology. The special boron alloy steel is heated to make the austenitic change. Then the red-hot sheet metal is put into a mold with cooling system to form. At the same time, it is quenched by mold and the steel plate organization transforms from austenite into martensite. Thus, the high strength structure of car is obtained.
Ping Hu, Ning Ma, Li-zhong Liu, Yi-Guo Zhu
Chapter 6. Microscopic Constitutive Models of Single Crystal and Polycrystal
A basic characteristic of crystal is that it consists of atoms or atom clusters arranged in a pattern that is periodic in 3D. The same atoms or atom clusters repeat at intervals in any orientation, and the intervals are called period. It should be noted that the period is different in different orientation.
Ping Hu, Ning Ma, Li-zhong Liu, Yi-Guo Zhu
Chapter 7. Hot Forming Simulation Algorithms of High-Strength Steels
Sheet metal stamping is based on the large plastic deformation of metal, with high nonlinear mechanical characteristics of geometry, physics, and boundary friction. In the traditional stamping process, it is necessary to design and manufacture prototypes, with many trial-productions and commissionings, for the design and manufacture of stamping tools, the determination of the blank’s shape and size, and the planning of stamping processes and parameters. It is a process of trial and error, resulting in large consumption of manpower, material and financial resources, high production costs, and long cycle.
Ping Hu, Ning Ma, Li-zhong Liu, Yi-Guo Zhu
Chapter 8. Numerical Simulation of High Strength Steel Plate’s Hot Forming
Based on the multi-field coupled constitutive relationships, nonlinear, and large-deformation dynamic explicit and implicit algorithm of hot forming, a new numerical simulation module about multi-field coupled hot forming is developed, which emerges with our independently developed commercial software KMAS (King-Mesh Analysis System).
Ping Hu, Ning Ma, Li-zhong Liu, Yi-Guo Zhu
Chapter 9. Features of Hot Forming Graded Composite Material and Its Experiment and Simulation
A high martensite transformation rate can be obtained by hot forming process, and therefore parts with high strength and hardness can be achieved. At the same time, a new type of composite metal body structural parts with gradient hardness and strength along the thickness and length direction can be achieved through the special duct design and manufacturing process. The productive process is a “natural formation” by hot forming without the need for composite bonding, welding, riveting, or other connecting techniques. This process not only provides a new way to choose body material, but also conduces to the controllable design of the material’s properties.
Ping Hu, Ning Ma, Li-zhong Liu, Yi-Guo Zhu
Chapter 10. Simulation and Optimization on Service Performance of Hot Forming Parts
Hot forming parts are most suitable for the body structural parts due to their ultra-high strength and hardness. This chapter will focus on the following questions such as how to evaluate the service performance of hot forming parts, how to optimize and design the service properties, and how to improve the service performance of the body structural parts by means of simulations and experiments.
Ping Hu, Ning Ma, Li-zhong Liu, Yi-Guo Zhu
Theories, Methods and Numerical Technology of Sheet Metal Cold and Hot Forming
Ping Hu
Ning Ma
Li-zhong Liu
Yi-guo Zhu
Copyright Year
Springer London
Electronic ISBN
Print ISBN

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