The design, control, and optimization of forming processes require (1) analytical knowledge regarding metal flow, stresses, and heat transfer, as well as (2) technological information related to lubrication, heating and cooling techniques, material handling, die design and manufacture, and forming equipment. The purpose of using analysis in metal forming is to investigate the mechanics of plastic deformation processes, with the following major objectives. • Establishing the kinematic relationships (shape, velocities, strain-rates, and strains) between the undeformed part (billet, blank, or preform) and the deformed part (product); i.e., predicting metal flow during the forming operation. This objective includes the prediction of temperatures and heat transfer, since these variables greatly influence local metal-flow conditions. • Establishing the limits of formability or producibility; i.e., determining whether it is possible to perform the forming operation without causing any surface or internal defects (cracks or folds) in the deforming material. • Predicting the stresses, the forces, and the energy necessary to carry out the forming operation. This information is necessary for tool design and for selecting the appropriate equipment, with adequate force and energy capabilities, to perform the forming operation. Thus, the mechanics of deformation provides the means for determining how the metal flows, how the desired geometry can be obtained by plastic deformation, and what the expected mechanical properties of the produced part are. For understanding the variables of a metal-forming process, it is best to consider the process as a system, as illustrated in Fig. 2.1 in Chap. 2. The interaction of most significant variables in metal forming are shown, in a simplified manner, in Fig. 3.1. It is seen that for a given billet or blank material and part geometry, the speed of deformation influences strain-rate and flow stress. Deformation speed, part geometry, and die temperature influence the temperature distribution in the formed part. Finally, flow stress, friction, and part geometry determine metal flow, forming load, and forming energy. In steady-state flow (kinematically), the velocity field remains unchanged, as is the case in the extrusion process; in nonsteadystate flow, the velocity field changes continuously with time, as is the case in upset forging.
Die design optimization on sheet metal forming with considering the phenomenon of springback to improve product quality
