Sheet metal products may be found all over the place. They encompass a wide range of consumer and industrial items, including beverage cans, cookware, filing cabinets, metal desks, appliances, and automobile bodywork. It's also utilised as building and housing panels in the construction sector. In sectors ranging from automotive to aeronautics, packaging, and home appliances, numerical modelling of sheet metal forming processes has become an important tool for the design of components and their forming processes. Sheet metal forming encompasses a diverse set of techniques that produce pieces for a wide range of applications, both visible and invisible. Drawing, stamping, and roll forming are popular examples of forming processes, but there are also less well-known examples such as explosive and magnetic pulse forming. The majority of sheet metal production operations take place at room temperature. Hot stamping is used on occasion to improve formability and reduce forming stresses on the machines. Titanium alloys and different high-strength steels are common materials used in hot stamping processes.
This book, based on the state of art knowledge, represents a major step in understanding the various aspects of sheet metal forming processes. The book is well designed based on different chapters and explains in-depth about process parameters in drawing, engineering optimization, thinning optimization, and spring back optimization. A logical-based discussion has been tried to make for better understanding of the subject matter. It also deals with fracture optimization, gray wolf optimizer, wrinkling optimization, and spring back optimization. The book explores all the important aspects of sheet metal forming in the present-day scenario. It elucidates the different techniques and methods used in this subject matter. The various subfields of this discipline along with technological progress that have future implications are glanced at in great detail. This book is meant for students who are looking for an elaborate reference on Sheet metal forming.
Preface
1. Introduction to Metal Forming
1. Introduction
2. Drawing/Deep Drawing Process
3. State of Stress in Deep Drawing
4. Description and Significance of Intrinsic Sheet Metal Properties
5. Formability of Sheet Metal
6. Strain-Defined Failure-Limit Curves
7. Construction of Forming-Limit Diagram
8. Thickness Gradient
9. Conclusion
References
2. Process Parameters in Drawing
1. Introduction
2. Blank-Holding Force
3. Friction in Drawing
4. Frictional Problems in Deep Drawing
5. Contact Regions in Deep Drawing
6. Lubrication Mechanism in Deep Drawing
7. Micro mechanism
8. Generalized Stribeck Curve
9. How to Control Friction Level
10. Ploughing and Adhesion
11. Friction and Drawability
12. Process Improvements
13. Die Profile Radius and Punch-Nose Radius
14. Conclusion
References
3. Failures in Drawing
1. Introduction
2. Thinning and Thickening Behavior
3. Wrinkling in Forming
4. Springback
5. Fracture
6. Conclusion
References
4. Engineering Optimization
1. Introduction
2. Optimization
3. Classification of Optimization Problems
4. Local Search Methods
5. Global Search Methods
6. Developments in Optimization Approaches
7. Bioinspired Algorithm
8. Conclusion
References
5. Thinning Optimization: Cohort Intelligence
1. Introduction
2. Cohort Intelligence Algorithm
3. General Constrained Optimization Problem
4. Static Penalty Function Metho and Dynamic Penalty Function
5. Proposed Innovative Methodology
6. Configurations of Components
7. Sealing Cover
8. Selection of Process Parameters and Performance Measure
9. Numerical Investigations: Taguchi Design of Experiments
10. Analysis of Variance
11. Objective Function Formulation
12. Validation: Numerical simulation
13. Experimental Validation
14. Conclusion
References
6. Springback Optimization: Flower Pollination
1. Introduction
2. Flower Pollination
3. Flower Pollination-Flowchart
4. Pseudocode
5. Selection of Process Parameters and Performance Measure
6. Numerical Investigations: Taguchi Design of Experiments
7. Analysis of Variance
8. Objective Function Formulation
9. Validation: Numerical Simulation
10. Conclusion
References
7. Fracture Optimization: Genetic Algorithm Approach
1. Introduction
2. Tail Cap
3. Selection of Process Parameters and Performance Measure
4. Numerical lnvestigations: Taguchi Design of Experiments
5. Analysis of Variance
6. Conclusion
References
8. Thinning Optimization of Punch Plate: Gray Wolf Optimizer
1. Introduction
2. Inspiration
3. Mathematical Model and Algorithm
4. Pseudocode
5. Penalty Function
6. Numerical Investigations: Taguchi Design of Experiments
7. Analysis of Variance
8. Objective Function Formulation
9. Results
10. Validation: Numerical Simulation
11. Conclusion
References
9. Wrinkling Optimization: Firefly Algorithm
1. Introduction
2. Behavior of Fireflies
3. Firefly Algorithm
4. Connector
5. Selection of Process Parameters and Performance Measure
6. Numerical Investigations: Taguchi Design of Experiments
7. Analysis of Variance
8. Validation: Numerical Simulation
9. Conclusion
References
10. Thickness Gradient Optimization: Ant Lion
1. Introduction
2. Pseudocode of ALO Algorithm
3. Selection of Process Parameters and Performance Measure
4. Results
5. Validation: Numerical Simulation
6. Conclusion
References
11. Springback Optimization: Cuckoo Search
1. Introduction
2. Cuckoo Breeding Behavior
3. Levy Flights
4. Cuckoo Search
5. Punch Plate
6. Selection of Process Parameters and Performance Measure
7. Numerical Investigations: Taguchi Design of Experiments
8. Analysis of Variance
9. Objective Function Formulation
10. Conclusion
References
Index
Reagan Christopher is a Research Professor at College of Engineering, Yucatan. He has received his Ph.D. in Mechanical Engineering & Metallurgy from Technological University, Minas Gerais. His research work in the fields of smart materials, metal work and alloys have won him several awards. Christopher has authored and edited numerous articles, journal papers and book chapters in the field of manufacturing technologies, metal forming, materials science and engineering. He is an active member of several scientific and technical societies.
