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Table of Contents
Preface; Acknowledgements; Contents; 1 Introduction; 1.1 Introduction; 1.2 Plastic Deformation of Materials; 1.3 Forming Process; 1.3.1 Cold Forming; 1.3.2 Warm Forming; 1.3.3 Hot Forming; 1.4 Metal-Forming Process and System; 1.5 Challenges in Metal-Formed Product Development; 1.5.1 Multidomains Involved in Metal-Formed Product Development; 1.5.2 Design of the Deformed Parts; 1.5.3 Process and Process Parameter Configuration; 1.5.4 Die Design and Its Service Life Analysis; 1.5.5 Defect Formation, Prediction, and Avoidance; 1.5.6 Optimization of Metal-Forming System; 1.6 Summary; References
2 Rigid-Plastic Finite Element Method and FE Simulation2.1 Introduction; 2.2 Modeling and Simulation; 2.3 Rigid-Plastic Finite Element Method; 2.3.1 Cartesian Tensor Representation; 2.3.2 Basic of Rigid-Plastic Finite Element Method; 2.3.3 Finite Element Simulation; 2.4 FE Simulation of Metal-Forming Systems; 2.4.1 Modeling of Die and Workpiece; 2.4.2 Modeling of Frictional Behaviors; 2.5 Geometric Symmetry in FE Simulation; 2.6 Validation and Verification of FE Simulation; 2.7 Summary; References; 3 Evaluation of Forming System Design; 3.1 Introduction
3.2 Evaluation of Metal-Forming Systems3.2.1 Factors Affecting the Design of Metal-Forming Systems; 3.2.2 Design of Deformed Parts; 3.2.2.1 Experimental Realization of the Twelve Design Scenarios; 3.2.2.2 Simulation and Analysis of the Twelve Design Scenarios; 3.2.3 Process and Die Design; 3.2.4 Simulation-Aided Evaluation of Metal-Forming Systems; 3.3 Realization of CAE Simulation; 3.3.1 Simulation Procedure; 3.3.2 Integrated Simulation Framework; 3.4 Evaluation Methodology; 3.4.1 Deformation Load; 3.4.2 Effective Strain; 3.4.3 Damage Factor; 3.4.4 Maximum Effective Stress
3.4.5 Deformation Homogeneity3.4.6 Evaluation Criterion; 3.5 Case Studies; 3.6 Summary; References; 4 Die Design and Service Life Analysis; 4.1 Introduction; 4.2 Die Performance and Service Life; 4.3 Stress-Based Die Design; 4.3.1 Prestress in Design; 4.3.2 Die Working Stress; 4.4 Die Fatigue Life Analysis; 4.4.1 Stress-Life Approach; 4.4.2 Strain-Life Approach; 4.4.3 Die Fatigue Life Assessment; 4.5 Case Studies; 4.5.1 Case Study 1; 4.5.2 Case Study 2; 4.5.3 Case Study 3; 4.5.3.1 Design of Metal-Forming System; 4.5.3.2 Integrated Simulation of Forming System
4.5.3.3 Procedure for Extraction of Simulation Results4.6 Summary; References; 5 Flow-Induced Defects in Multiscaled Plastic Deformation; 5.1 Introduction; 5.2 Flow-Induced Defect in Forming Processes; 5.2.1 Flow-Induced Defect in Forming of Axisymmetric Parts with Flanged Features; 5.2.2 Flow-Induced Defect in Forming of Non-asymmetrically Mesoscaled Parts; 5.2.2.1 Mesoforming Experiment; 5.2.2.2 FE Simulation; 5.3 Defect Avoidance in Forming Process; 5.3.1 Employment of Spring-Driven Die Insert Structure; 5.3.1.1 Sliding Die Insert Design and Material Flow Behaviors
2 Rigid-Plastic Finite Element Method and FE Simulation2.1 Introduction; 2.2 Modeling and Simulation; 2.3 Rigid-Plastic Finite Element Method; 2.3.1 Cartesian Tensor Representation; 2.3.2 Basic of Rigid-Plastic Finite Element Method; 2.3.3 Finite Element Simulation; 2.4 FE Simulation of Metal-Forming Systems; 2.4.1 Modeling of Die and Workpiece; 2.4.2 Modeling of Frictional Behaviors; 2.5 Geometric Symmetry in FE Simulation; 2.6 Validation and Verification of FE Simulation; 2.7 Summary; References; 3 Evaluation of Forming System Design; 3.1 Introduction
3.2 Evaluation of Metal-Forming Systems3.2.1 Factors Affecting the Design of Metal-Forming Systems; 3.2.2 Design of Deformed Parts; 3.2.2.1 Experimental Realization of the Twelve Design Scenarios; 3.2.2.2 Simulation and Analysis of the Twelve Design Scenarios; 3.2.3 Process and Die Design; 3.2.4 Simulation-Aided Evaluation of Metal-Forming Systems; 3.3 Realization of CAE Simulation; 3.3.1 Simulation Procedure; 3.3.2 Integrated Simulation Framework; 3.4 Evaluation Methodology; 3.4.1 Deformation Load; 3.4.2 Effective Strain; 3.4.3 Damage Factor; 3.4.4 Maximum Effective Stress
3.4.5 Deformation Homogeneity3.4.6 Evaluation Criterion; 3.5 Case Studies; 3.6 Summary; References; 4 Die Design and Service Life Analysis; 4.1 Introduction; 4.2 Die Performance and Service Life; 4.3 Stress-Based Die Design; 4.3.1 Prestress in Design; 4.3.2 Die Working Stress; 4.4 Die Fatigue Life Analysis; 4.4.1 Stress-Life Approach; 4.4.2 Strain-Life Approach; 4.4.3 Die Fatigue Life Assessment; 4.5 Case Studies; 4.5.1 Case Study 1; 4.5.2 Case Study 2; 4.5.3 Case Study 3; 4.5.3.1 Design of Metal-Forming System; 4.5.3.2 Integrated Simulation of Forming System
4.5.3.3 Procedure for Extraction of Simulation Results4.6 Summary; References; 5 Flow-Induced Defects in Multiscaled Plastic Deformation; 5.1 Introduction; 5.2 Flow-Induced Defect in Forming Processes; 5.2.1 Flow-Induced Defect in Forming of Axisymmetric Parts with Flanged Features; 5.2.2 Flow-Induced Defect in Forming of Non-asymmetrically Mesoscaled Parts; 5.2.2.1 Mesoforming Experiment; 5.2.2.2 FE Simulation; 5.3 Defect Avoidance in Forming Process; 5.3.1 Employment of Spring-Driven Die Insert Structure; 5.3.1.1 Sliding Die Insert Design and Material Flow Behaviors