Electrically Assisted Forming

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.

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.

In this collection, scientists and engineers from across industry, academia, and government present their latest improvements and innovations in all aspects of metal forming science and technology, with the intent of facilitating linkages and collaborations among these groups. Chapters cover the breadth of metal forming topics, from fundamental science to industrial application.

These ESAFORM 2024 conference proceedings cover a wide range of topics: 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; Optimization and inverse analysis in forming; Machining, Cutting and severe plastic deformation processes; Material behavior modelling; New and advanced numerical strategies for material forming; Non-conventional processes; Polymer processing and thermomechanical properties; Sustainability on material forming. Keywords: WAAM Technology, Fused deposition Modeling (FDM), Fiber Composite Printers, Ultrasonic Powder Atomization, Finite Element Modeling (FEM), Laser Powder Bed Fusion (L-PBF), Rapid Prototyping in Additive Manufacturing, Directed Energy Deposition (DED), GTAW Droplet Deposition, Deep Learning, Thermoplastic Pultrusion, Textile Reinforcements, Thermoforming Simulation, New Sustainable Materials, Non-Crimp Fabrics, CFRP Scraps, PEEK Composites, Thermoplastic Sheets, Flax/PP Composites.

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.

Analysis and Optimization of Sheet Metal Forming Processes comprehensively covers sheet metal forming, from choosing materials, tools and the forming method to optimising the entire process through finite element analysis and computer-aided engineering. Beginning with an introduction to sheet metal forming, the book provides a guide to the various techniques used within the industry. It provides a discussion of sheet metal properties relevant to forming processes, such as ductility, formability, and strength, and analyses how materials should be selected with factors including material properties, cost, and availability. Forming processes including shearing, bending, deep drawing, and stamping are also discussed, along with tools such as dies, punches, and moulds. Simulation and modelling are key to optimising the sheet metal forming process, including finite element analysis and computer-aided engineering. Other topics included are quality control, design, industry applications, and future trends. The book will be of interest to students and professionals working in the field of sheet metal and metal forming, materials science, mechanical engineering, and metallurgy.

This book comprises the select proceedings of the International Conference on Materials, Design and Manufacturing for Sustainable Environment (ICMDMSE 2020). The primary focus is on emerging materials and cutting-edge manufacturing technologies for sustainable environment. The book covers a wide range of topics such as advanced materials, vibration, tribology, finite element method (FEM), heat transfer, fluid mechanics, energy engineering, additive manufacturing, robotics and automation, automobile engineering, industry 4.0, MEMS and nanotechnology, optimization techniques, condition monitoring, and new paradigms in technology management. Contents of this book will be useful to students, researchers, and practitioners alike.

This book presents the findings of research projects from the Transregional Collaborative Research Centre 73. These proceedings are the result of years of research into sheet–bulk metal forming. The book discusses the challenges posed by simulating sheet–bulk metal forming. It takes into account the different phenomena characteristic to both sheet and bulk forming fields, and explores the demands this makes on modelling the processes. It then summarizes the research, and presents from a practitioner's point of view. This means the book is of interest to and helps both academics and industrial engineers within the field of sheet–bulk metal forming.

Edited by prominent researchers and with contributions from experts in their individual areas, Intelligent Energy Field Manufacturing: Interdisciplinary Process Innovations explores a new philosophy of engineering. An in-depth introduction to Intelligent Energy Field Manufacturing (EFM), this book explores a fresh engineering methodology that not only integrates but goes beyond methodologies such as Design for Six Sigma, Lean Manufacturing, Concurrent Engineering, TRIZ, green and sustainable manufacturing, and more. This book gives a systematic introduction to classic non-mechanical manufacturing processes as well as offering big pictures of some technical frontiers in modern engineering. The book suggests that any manufacturing process is actually a process of injecting human intelligence into the interaction between material and the various energy fields in order to transfer the material into desired configurations. It discusses technological innovation, dynamic M-PIE flows, the generalities of energy fields, logic functional materials and intelligence, the open scheme of intelligent EFM implementation, and the principles of intelligent EFM. The book takes a highly interdisciplinary approach that includes research frontiers such as micro/nano fabrication, high strain rate processes, laser shock forming, materials science and engineering, bioengineering, etc., in addition to a detailed treatment of the so called "non-traditional" manufacturing processes, which covers waterjet machining, laser material processing, ultrasonic material processing, EDM/ECM, etc. Filled with illustrative pictures, figures, and tables that make technical materials more absorbable, the book cuts across multiple engineering disciplines. The majority of books in this area report the facts of proven knowledge, while the behind-the-scenes thinking is usually neglected. This book examines the big picture of manufacturing in depth before diving into the deta