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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.
Book Synopsis Electrically Assisted Forming by : Wesley A. Salandro
Download or read book Electrically Assisted Forming written by Wesley A. Salandro and published by Springer. This book was released on 2014-08-16 with total page 366 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.
Single Point Incremental Forming (SPIF) is a die-less sheet metal forming method. Because SPIF does not use custom tooling, this process allows for parts to be made at low cost and short lead times. In this thesis electric current is applied through the tool to alter the formability of samples formed with SPIF. The research goal of this work is to determine if formability is effected by resistive heating alone or if there is some formability change due to the current interacting with the material. An apparatus that allows electrical current to be applied through the tool during forming is designed and implemented. A method is also developed to allow the contact area between the tool and sheet to be estimated, with particular focus on developing a method that allows for experimental measurement. The effect of applied current on formability is estimated by evaluating the maximum wall angle that can be formed in a single pass, using a variety of tool sizes and current settings. Using the contact area model to estimate current density, a signicant increase in formability is found at a current density range that agrees with previously published literature on electrically assisted forming of the same material. The results show that across multiple tool sizes, a significant increase in formability is observed when applying a current density (A/mm2) larger than the current threshold density published in the literature. A study is also performed to test the performance of a set of novel tool shapes. By using parabolic tools, it was found that formability can be improved while maintaining low surface roughness. Finally, a series of case studies are presented documenting the production several parts for a variety of design groups and researchers at Queen's University. These case studies provide examples for the uses of SPIF, as well as document the methods used to produce these parts in greater detail than is present in the literature.
Book Synopsis Improvements on Single Point Incremental Forming Through Electrically Assisted Forming, Contact Area Prediction and Tool Development by : David Willliam Adams
Download or read book Improvements on Single Point Incremental Forming Through Electrically Assisted Forming, Contact Area Prediction and Tool Development written by David Willliam Adams and published by . This book was released on 2013 with total page 380 pages. Available in PDF, EPUB and Kindle. Book excerpt: Single Point Incremental Forming (SPIF) is a die-less sheet metal forming method. Because SPIF does not use custom tooling, this process allows for parts to be made at low cost and short lead times. In this thesis electric current is applied through the tool to alter the formability of samples formed with SPIF. The research goal of this work is to determine if formability is effected by resistive heating alone or if there is some formability change due to the current interacting with the material. An apparatus that allows electrical current to be applied through the tool during forming is designed and implemented. A method is also developed to allow the contact area between the tool and sheet to be estimated, with particular focus on developing a method that allows for experimental measurement. The effect of applied current on formability is estimated by evaluating the maximum wall angle that can be formed in a single pass, using a variety of tool sizes and current settings. Using the contact area model to estimate current density, a signicant increase in formability is found at a current density range that agrees with previously published literature on electrically assisted forming of the same material. The results show that across multiple tool sizes, a significant increase in formability is observed when applying a current density (A/mm2) larger than the current threshold density published in the literature. A study is also performed to test the performance of a set of novel tool shapes. By using parabolic tools, it was found that formability can be improved while maintaining low surface roughness. Finally, a series of case studies are presented documenting the production several parts for a variety of design groups and researchers at Queen's University. These case studies provide examples for the uses of SPIF, as well as document the methods used to produce these parts in greater detail than is present in the literature.
Book Synopsis Investigation of Electrical-Assisted Forming at the Microscale by : Michael S. Siopis
Download or read book Investigation of Electrical-Assisted Forming at the Microscale written by Michael S. Siopis and published by . This book was released on 2009 with total page 170 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Incremental Sheet Forming (ISF) exempts use of dies and reduces cost for manufacturing complex parts. Sheet metal forming is used for producing high-quality components in automotive, aerospace, and medical industries. This book covers the benefits of this new technology, including the process parameters along with various techniques. Each variant of this novel process is discussed along with the requirements of machinery and hardware. In addition, appropriate guidelines are also suggested regarding the relationship between process parameters and aspects of ISF process in order to ensure the applicability of the process on the industrial scale. This book will be a useful asset for researchers, engineers in manufacturing industries, and postgraduate level courses.
Book Synopsis Incremental Sheet Forming Technologies by : Ajay
Download or read book Incremental Sheet Forming Technologies written by Ajay and published by CRC Press. This book was released on 2020-09-24 with total page 179 pages. Available in PDF, EPUB and Kindle. Book excerpt: Incremental Sheet Forming (ISF) exempts use of dies and reduces cost for manufacturing complex parts. Sheet metal forming is used for producing high-quality components in automotive, aerospace, and medical industries. This book covers the benefits of this new technology, including the process parameters along with various techniques. Each variant of this novel process is discussed along with the requirements of machinery and hardware. In addition, appropriate guidelines are also suggested regarding the relationship between process parameters and aspects of ISF process in order to ensure the applicability of the process on the industrial scale. This book will be a useful asset for researchers, engineers in manufacturing industries, and postgraduate level courses.
The objectives of this project are to establish the scientific bases, engineering technologies and energy/emission impact of a novel dieless forming process, Double side Incremental Forming (DSIF), and to explore the effectiveness of its hybrid variation, Electrical-Assisted Double Side Incremental Forming (EADSIF), on increasing the formability of metallic sheets. The scope of this project includes: (1) the analysis of environmental performance of the proposed new process as compared to conventional sheet metal forming processes; (2) the experimental investigation of the process capabilities of DSIF and EADSIF via the self-designed and newly established lab-scale EADSIF equipment; (3) the development of the essential software in executing the new proposed process, i.e., the toolpath generation algorithms; and finally (4) the exploration of the electricity effect on material deformation. The major accomplishments, findings and conclusions obtained through this one and a half years exploratory project are: (1) The first industrial medium-size-scale DSIF machine using two hexapods, capable of handling a sheet area up to 675 mm x 675 mm, was successfully completed at Ford. (2) The lab-scale of the DSIF machine was designed, fabricated and assembled to form a workpiece up to 250 mm x 250 mm. (3) Parts with arbitrary freeform double-curvatures using the genetic, not geometric-specific tooling were successfully formed using both machines. (4) The methodology of the life cycle analysis of DSIF was developed and energy consumption was measured and compared to conventional forming processes. It was found that the DSIF process can achieve 40% to 90% saving when the number of parts produced is less than 50. Sensitivity analysis was performed and showed that even at very large number of produced parts (greater than 2000), incremental forming saves at least 5% of the energy used in conventional forming. (5) It was proposed to use the offset between the two universal tools in DSIF to actively create a squeezing effect on sheet metal and therefore, increase the geometric accuracy. The idea was confirmed through both experimental and numerical validations. (6) A novel toolpath strategy, i.e., the so-called In-to-out toolpath or accumulative toolpath, was proposed to further increase formability and geometric accuracy compared to the SPIF configuration. A dimensional form accuracy of 1 mm can be achieved using the new strategy. (7) The effect of electricity on magnesium alloy was experimentally investigated. It was found that the formability has a ridge with respect to the applied current density and pulse duration. This finding implies that there are multiple choices of process parameters that are workable depending on the desired microstructure. The above results demonstrated that DSIF/EADSIF is a promising forming technology that can create impacts in revolutionizing how the prototyping and small volume production of sheet metals will be fabricated, i.e., it can (1) eliminate the need of casting and machining of drawing dies; (2) tailor material utilization to function requirement therefore achieving a light weight product; (3) reduce the amount of sheet metal scraps; and (4) shorten the engineering and manufacturing time for sheet metal parts from the current 8 ≈ 25 weeks to less than 1 week after the technology is fully developed. DSIF/EADSIF can be implemented in aerospace, automotive and appliance industries, or be used for producing personalized and point-of-use products in medical industry. Our analysis has shown that once developed, verified and demonstrated, the implementation and growth of DSIF will increase U.S. manufacturing competitiveness, advance machine tool and software industries, and create opportunities for emerging clean energy and low-carbon economy with estimated energy savings of 11 TBtu and CO2 reduction of 1 million tons per year. The work has been disseminated into three (3) journal articles and two (2) provisional patent submissions. A new company has been spun off from this research group aiming to commercialize the technology. A team, consisted of Northwestern Kellogg Business school students and Northwestern McCormick Engineering school graduate students, has independently examined business facts and business models, and has assisted in developing go-to-market strategy. One of the key recommendations for utilizing the full potential of this work is to demonstrate the DSIF/EADSIF concept in a true large-scale industrial setup, i.e., being able to form sheet size of 1.5 m x 1.5 m, where technical challenges, such as machine design, shape compensation, dynamic effect on geometrical accuracy, need to be further explored.
Book Synopsis A Hybrid Forming System by :
Download or read book A Hybrid Forming System written by and published by . This book was released on 2012 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: The objectives of this project are to establish the scientific bases, engineering technologies and energy/emission impact of a novel dieless forming process, Double side Incremental Forming (DSIF), and to explore the effectiveness of its hybrid variation, Electrical-Assisted Double Side Incremental Forming (EADSIF), on increasing the formability of metallic sheets. The scope of this project includes: (1) the analysis of environmental performance of the proposed new process as compared to conventional sheet metal forming processes; (2) the experimental investigation of the process capabilities of DSIF and EADSIF via the self-designed and newly established lab-scale EADSIF equipment; (3) the development of the essential software in executing the new proposed process, i.e., the toolpath generation algorithms; and finally (4) the exploration of the electricity effect on material deformation. The major accomplishments, findings and conclusions obtained through this one and a half years exploratory project are: (1) The first industrial medium-size-scale DSIF machine using two hexapods, capable of handling a sheet area up to 675 mm x 675 mm, was successfully completed at Ford. (2) The lab-scale of the DSIF machine was designed, fabricated and assembled to form a workpiece up to 250 mm x 250 mm. (3) Parts with arbitrary freeform double-curvatures using the genetic, not geometric-specific tooling were successfully formed using both machines. (4) The methodology of the life cycle analysis of DSIF was developed and energy consumption was measured and compared to conventional forming processes. It was found that the DSIF process can achieve 40% to 90% saving when the number of parts produced is less than 50. Sensitivity analysis was performed and showed that even at very large number of produced parts (greater than 2000), incremental forming saves at least 5% of the energy used in conventional forming. (5) It was proposed to use the offset between the two universal tools in DSIF to actively create a squeezing effect on sheet metal and therefore, increase the geometric accuracy. The idea was confirmed through both experimental and numerical validations. (6) A novel toolpath strategy, i.e., the so-called In-to-out toolpath or accumulative toolpath, was proposed to further increase formability and geometric accuracy compared to the SPIF configuration. A dimensional form accuracy of 1 mm can be achieved using the new strategy. (7) The effect of electricity on magnesium alloy was experimentally investigated. It was found that the formability has a ridge with respect to the applied current density and pulse duration. This finding implies that there are multiple choices of process parameters that are workable depending on the desired microstructure. The above results demonstrated that DSIF/EADSIF is a promising forming technology that can create impacts in revolutionizing how the prototyping and small volume production of sheet metals will be fabricated, i.e., it can (1) eliminate the need of casting and machining of drawing dies; (2) tailor material utilization to function requirement therefore achieving a light weight product; (3) reduce the amount of sheet metal scraps; and (4) shorten the engineering and manufacturing time for sheet metal parts from the current 8 ≈ 25 weeks to less than 1 week after the technology is fully developed. DSIF/EADSIF can be implemented in aerospace, automotive and appliance industries, or be used for producing personalized and point-of-use products in medical industry. Our analysis has shown that once developed, verified and demonstrated, the implementation and growth of DSIF will increase U.S. manufacturing competitiveness, advance machine tool and software industries, and create opportunities for emerging clean energy and low-carbon economy with estimated energy savings of 11 TBtu and CO2 reduction of 1 million tons per year. The work has been disseminated into three (3) journal articles and two (2) provisional patent submissions. A new company has been spun off from this research group aiming to commercialize the technology. A team, consisted of Northwestern Kellogg Business school students and Northwestern McCormick Engineering school graduate students, has independently examined business facts and business models, and has assisted in developing go-to-market strategy. One of the key recommendations for utilizing the full potential of this work is to demonstrate the DSIF/EADSIF concept in a true large-scale industrial setup, i.e., being able to form sheet size of 1.5 m x 1.5 m, where technical challenges, such as machine design, shape compensation, dynamic effect on geometrical accuracy, need to be further explored.
Book Synopsis Friction Assisted Forming by : T Nakamura
Download or read book Friction Assisted Forming written by T Nakamura and published by . This book was released on 1989 with total page 9 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Vibration-assisted Forming by : Isa Yousif Bu-Mtaia
Download or read book Vibration-assisted Forming written by Isa Yousif Bu-Mtaia and published by . This book was released on 1993 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Investigation of Thermal and Mechanical Effects During Electrically-assisted Microforming by :
Download or read book Investigation of Thermal and Mechanical Effects During Electrically-assisted Microforming written by and published by . This book was released on 2013 with total page 104 pages. Available in PDF, EPUB and Kindle. Book excerpt:
These proceedings present papers on Additive Manufacturing, Composites Forming Processes, Extrusion and Drawing, Forging and Rolling, Formability of Metallic Materials, Friction and Wear in Metal Forming, Incremental and Sheet Metal Forming, Innovative Joining by Forming Technologies, Lionel Fourment MS on Optimization and Inverse Analysis in Forming, Machining and Cutting, Material Behavior Modelling, New and Advanced Numerical Strategies for Material Forming, Non-Conventional Processes, Polymer Processing and Thermomechanical Properties, Sustainability on Material Forming, and Property-Controlled Forming.
Book Synopsis Material Forming by : Lukasz Madej
Download or read book Material Forming written by Lukasz Madej and published by Materials Research Forum LLC. This book was released on 2023-04-25 with total page 2163 pages. Available in PDF, EPUB and Kindle. Book excerpt: These proceedings present papers on Additive Manufacturing, Composites Forming Processes, Extrusion and Drawing, Forging and Rolling, Formability of Metallic Materials, Friction and Wear in Metal Forming, Incremental and Sheet Metal Forming, Innovative Joining by Forming Technologies, Lionel Fourment MS on Optimization and Inverse Analysis in Forming, Machining and Cutting, Material Behavior Modelling, New and Advanced Numerical Strategies for Material Forming, Non-Conventional Processes, Polymer Processing and Thermomechanical Properties, Sustainability on Material Forming, and Property-Controlled Forming.
A process for forming a sheet metal component using an electric current passing through the component is provided. The process can include providing a double side incremental forming machine, the machine operable to perform a plurality of double side incremental deformations on the sheet metal component and also apply an electric direct current to the sheet metal component during at least part of the forming. The direct current can be applied before or after the forming has started and/or be terminated before or after the forming has stopped. The direct current can be applied to any portion of the sheet metal. The electrical assistance can reduce the magnitude of force required to produce a given amount of deformation, increase the amount of deformation exhibited before failure and/or reduce any springback typically exhibited by the sheet metal component.
Book Synopsis Electrical-assisted Double Side Incremental Forming and Processes Thereof by :
Download or read book Electrical-assisted Double Side Incremental Forming and Processes Thereof written by and published by . This book was released on 2014 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: A process for forming a sheet metal component using an electric current passing through the component is provided. The process can include providing a double side incremental forming machine, the machine operable to perform a plurality of double side incremental deformations on the sheet metal component and also apply an electric direct current to the sheet metal component during at least part of the forming. The direct current can be applied before or after the forming has started and/or be terminated before or after the forming has stopped. The direct current can be applied to any portion of the sheet metal. The electrical assistance can reduce the magnitude of force required to produce a given amount of deformation, increase the amount of deformation exhibited before failure and/or reduce any springback typically exhibited by the sheet metal component.
