Mechanics of materials in modern manufacturing methods and processing techniques

Front Cover......Page 1
Mechanics of Materials in Modern Manufacturing Methods and Processing Techniques......Page 4
Copyright Page......Page 5
Contents......Page 6
List of contributors......Page 14
About the Series editors......Page 18
 1.1 Introduction......Page 20
  1.2.1 Forging......Page 21
  1.2.2 Rolling......Page 23
  1.2.3 Wire drawing......Page 25
  1.2.4 Extrusion......Page 26
  1.2.5 Deep drawing......Page 29
  1.2.6 Bending......Page 30
  1.3.2 Slip-line field method......Page 32
  1.3.4 Upper bound method......Page 33
  1.3.6 Finite element method......Page 34
  1.3.7 Meshless method......Page 36
  1.3.9 Soft computing......Page 37
 1.4 Inverse modeling......Page 38
 1.5 Modeling of microstructure and surface integrity......Page 39
 1.6 A note on multiscale modeling of metal forming......Page 41
 1.7 Challenging issues......Page 42
 1.8 Conclusion......Page 43
 References......Page 44
 2.1 Introduction......Page 50
  2.1.1 Hydraulic autofrettage......Page 51
  2.1.2 Swage autofrettage......Page 52
  2.1.3 Explosive autofrettage......Page 53
  2.1.5 Rotational autofrettage......Page 54
 2.2 Numerical modeling of elastic–plastic problems......Page 56
   2.2.1.1 The von Mises yield criterion......Page 57
   2.2.1.2 Tresca yield criterion......Page 58
  2.2.2 Approaches for numerical modeling of elastic–plastic problems......Page 61
  2.3.1 Derivation of the weak form of the equilibrium equation......Page 63
  2.3.2 Formulation of elemental equations......Page 65
  2.3.3 Solution method......Page 69
 2.4 Typical results of FEM modeling of hydraulic and thermal autofrettage......Page 71
  2.4.1 Results of hydraulic autofrettage......Page 72
   2.4.1.1 Results for plane stress condition of hydraulic autofrettage......Page 73
   2.4.1.2 Results for plane strain end condition of hydraulic autofrettage......Page 76
  2.4.2 Results of thermal autofrettage......Page 77
   2.4.2.1 Results for plane stress end condition of thermal autofrettage......Page 80
   2.4.2.2 Results for open-ended condition of thermal autofrettage......Page 82
 2.5 Conclusion......Page 85
 References......Page 86
 3.1 Introduction......Page 90
  3.2.1 Rotationally symmetrical tube expansion......Page 93
  3.2.2 Hydroforming of polygonal cross sections......Page 100
  3.2.3 Hydroforming of tube branches......Page 104
  3.3.1 Necking and bursting......Page 108
  3.3.2 Wrinkling and buckling......Page 114
 3.4 Design of loading paths......Page 117
 3.5 Conclusion......Page 120
 References......Page 121
 4.1 Process classification......Page 130
  4.2.1 General setup and process principle......Page 131
   4.2.2.1 Electromagnetic pulse compression......Page 132
   4.2.2.2 Electromagnetic pulse expansion......Page 135
   4.2.2.3 Electromagnetic pulse forming of flat and preformed sheet metal......Page 137
  4.3.1 Analytical calculation of the acting loads......Page 142
  4.3.2 Numerical calculation of the process......Page 145
 4.4 Advantages and application fields of electromagnetic pulse forming......Page 150
   4.4.1.1 Electromagnetic pulse forming as a stand-alone process......Page 151
   4.4.1.2 Multiple-discharge electromagnetic pulse forming......Page 152
   4.4.1.3 Combined electromagnetic pulse and conventional forming......Page 153
  4.4.2 Joining......Page 155
  4.4.3 Cutting......Page 157
 References......Page 158
  5.1.2 Damage mechanisms......Page 162
  5.1.3 Advanced manufacturing technology: hot stamping......Page 163
  5.1.4 Concept and features of forming limit diagram......Page 164
  5.2.1 Forming limit prediction......Page 165
  5.2.2 Experimental methods for determining forming limits......Page 166
  5.2.3 Requirements for hot stamping applications......Page 168
  5.2.4 Advanced testing system for hot stamping applications......Page 169
  5.3.1 Constitutive equations......Page 170
  5.3.2 Advanced damage models......Page 172
  5.3.3 A set of unified constitutive equations for hot stamping......Page 174
  5.3.4 Modeling of forming limit diagrams......Page 175
  5.4.1 Overview of damage calibration techniques......Page 177
  5.4.2 An example of using thermomechanical uniaxial test data......Page 178
  5.4.3 Examples of using thermomechanical multiaxial tensile test data......Page 179
  5.5.1 Plane stress–based continuum damage mechanics material model......Page 181
  5.5.2 Principal strain–based continuum damage mechanics material model......Page 184
  5.5.3 Prediction of formability in hot forming......Page 189
 References......Page 190
  6.1.1 Pultrusion......Page 192
 6.2 Resin impregnation......Page 194
  6.2.1 Saturated pressure-driven flow......Page 195
  6.2.3 Permeability of fiber reinforcements......Page 196
  6.2.4 Unsaturated impregnation flow......Page 197
  6.3.1 Heat transfer......Page 199
  6.3.2 Cure kinetics and differential scanning calorimetry......Page 200
  6.3.3 Modeling considerations: simple models and state-of-the-art......Page 201
  6.4.1 The evolution of material properties......Page 202
  6.4.2 Mechanical modeling strategies......Page 203
  6.4.3 Assessment of the resultant residual stress fields and the verification......Page 205
  6.5.2 Die-entrance to flow front location, A1......Page 208
  6.5.3 Through liquid and gel states, A2......Page 209
 6.6 Conclusion......Page 210
 References......Page 211
 7.1 Introduction......Page 216
 7.2 Closed-loop principle of modeling......Page 217
  7.3.1 Slip-line method......Page 218
  7.3.2 Finite element modeling (finite element method)......Page 222
  7.3.3 Complementary methods......Page 228
  7.4.4 Burr formation and clean manufacturing......Page 232
  7.4.5 Cryogenic machining......Page 234
   7.5.1.1 Clamping devices and machining......Page 235
  7.5.2 Multiscale modeling in machining......Page 237
  7.5.3 Multiscale modeling in coating-substrate simulation......Page 239
 References......Page 241
 Further reading......Page 245
 8.1 Introduction......Page 248
  8.2.1 Kinematic modeling......Page 249
   8.2.2.1 Material modeling......Page 251
   8.2.2.2 Finite-element model setup......Page 252
   8.2.2.3 Results......Page 253
  8.3.1 Experimental setup and instrumentation......Page 254
   8.3.1.2 Surface metrology......Page 255
    Cutting forces......Page 256
    Chip formation......Page 258
 8.4 Conclusion and outlook......Page 259
 References......Page 260
 9.1 Introduction......Page 262
  9.2.1 Single-crystal-plasticity theory......Page 264
  9.2.2 Computational implementation......Page 266
  9.3.1 Experimental procedure......Page 267
  9.3.2 Finite-element model and material parameters......Page 268
   9.3.3.1 Prediction of cutting forces......Page 269
   9.3.3.3 Prediction of workpiece deformation......Page 271
  9.3.4 Discussion......Page 273
   9.3.4.1 Mesh-sensitivity analysis......Page 274
   9.3.4.2 Criteria of material-removal modeling......Page 275
   9.3.4.3 Material-removal modeling techniques......Page 276
  9.4.1 Experimental procedure......Page 277
  9.4.2 Computational modeling......Page 278
   9.4.3.2 Comparison of cutting forces......Page 281
   9.4.3.4 Discussion......Page 282
 9.5 Concluding remarks......Page 283
 References......Page 284
 10.1 Introduction......Page 288
  10.2.1 Microstructural evolution in machined surface......Page 289
  10.2.2 Microstructural evolution in chip......Page 292
   10.3.1.1 Dislocation density model......Page 294
   10.3.1.2 Dynamic recrystallization model......Page 295
   10.3.1.3 Phase-transformation model......Page 296
  10.3.2 Calculation of microstructural evolution......Page 297
 10.4 Microstructural evolution in ultrasonically assisted cutting......Page 298
  10.4.1 Microstructural evolution in machined surface with ultrasonically assisted cutting......Page 302
  10.4.2 Microstructural evolution in chip with ultrasonically assisted cutting......Page 307
 References......Page 313
 11.1 Introduction......Page 316
  11.2.1 Metal-cutting definition and energy considerations......Page 317
  11.2.3 Techniques for measuring residual stress......Page 320
  11.3.1 Origin of residual stresses in metal cutting......Page 322
  11.3.2 Residual stresses in difficult-to-cut materials......Page 324
   11.3.2.1 Nickel-based alloys......Page 326
   11.3.2.2 Titanium-based alloys......Page 328
   11.3.2.3 Austenitic stainless steels......Page 329
    AISI H13......Page 331
    AISI D2......Page 335
    AISI 52100......Page 336
  11.3.3 Effect of relative tool sharpness on residual stresses......Page 338
  11.3.4 Control of residual stresses in machining......Page 341
  11.4.1 Modeling and simulation considerations......Page 343
   11.4.2.1 Material constitutive model......Page 345
   11.4.2.2 Selection of material constitutive model......Page 351
   11.4.2.3 Contact model......Page 353
   11.4.3.1 Austenitic stainless steel AISI 316L......Page 354
   11.4.3.2 Nickel-based alloys Inconel 690......Page 356
   11.4.3.3 Case-hardened steels AISI H13 and AISI 52100......Page 357
   11.4.3.4 Oxygen-free high-conductivity copper......Page 358
  11.4.4 Procedure for comparing predicted and measured residual stresses......Page 360
   11.4.4.3 Extract the predicted residual stress from the FE model......Page 362
  11.4.5 Optimization of cutting conditions for improved residual stresses and surface roughness in machined components......Page 363
  11.5.1 Introduction......Page 365
  11.5.2 Corrosion resistance......Page 367
  11.5.3 Fatigue strength......Page 371
 11.6 Conclusion......Page 372
 References......Page 373
 12.1 Introduction......Page 380
 12.2 Shock wave and parameters......Page 382
  12.3.1 Taylor’s impact test......Page 384
  12.3.3 Flyer plate impact test......Page 385
  12.3.5 Shock impact in a shock tube......Page 386
  12.3.6 Laser-induced shock generation......Page 387
  12.4.1 Types of shock-generated defects......Page 388
   12.4.2.1 Grain size......Page 390
   12.4.2.3 Face-centered cubic metals: stacking fault energy......Page 392
   12.4.2.4 Hexagonal closed-packed metals: c/a ratio......Page 393
   12.4.2.5 Body-centered cubic metals......Page 394
   12.4.3.1 Peak pressure and pulse width......Page 395
  12.4.4 Other factors: residual strain......Page 397
 12.5 Theory of defect generation under shock: past theories and new perspectives......Page 399
 References......Page 403
 13.1 Introduction......Page 412
 13.2 Thermal behavior......Page 415
 13.3 Microstructural evolution......Page 418
 13.4 Residual stresses and distortions......Page 419
 13.5 Material flow......Page 422
 References......Page 429
 14.1 Introduction......Page 434
 14.2 History of friction modeling......Page 435
 14.3 Some popular friction models......Page 437
  14.3.2 Constant-friction model......Page 438
  14.3.3 Wanheim and Bay’s model......Page 439
  14.3.4 Asperity-based friction model......Page 440
  14.3.5 Plowing model......Page 453
 14.4 Friction in machining......Page 454
 14.5 Friction models in metal forming......Page 456
 14.6 Friction in solid-state welding......Page 457
 14.8 Challenging issues and directions for future research......Page 458
 14.9 Conclusion......Page 459
 References......Page 460
 Further reading......Page 463
Index......Page 464
Back Cover......Page 476