The program is based on the method for acquiring true stress-strain curves over large range of strains using engineering stress-strain curves obtained from a tensile test coupled with a finite element analysis. In the method, a tensile test is analyzed using a rigid-plastic finite element method combined with a perfect analysis model for its associated simple bar to provide the information of deformation.
With conventional forging, as the dies approach, the alloy plastically deforms and flows laterally touching the side walls of the die. The alloy continues to flow outside of the impression forming flash. a the flash thins it cools causing resistance to additional deformation. The cooled flash then adds pressure to the inside of the die cavity to promote metal flow into any design impressions that are unfilled.
The main advantage of incremental forming is that it is well suited for low cost prototyping or small batches of manufactured products. It can be used to create complex shapes with very simple tools. Because it is done with CAD/CAM the tool path can be created quickly and the changes are easy to apply. It can be done on any CNC milling machine or industrial robot, which also contributes to its cost-effectiveness.
Rolling involves passing metal between rollers to reduce the thickness of the material to a pre-determined size. The process utilizes a hammer and anvil or a drop hammer in larger machinery. Rolling can be achieved hot or cold. The cold method is often employed if the desired result is to toughen or harden the metal.
When it comes to manufacturing, there are a variety of different methods that can be used. Two such processes are extrusion and drawing. Both of these processes have their own set of advantages and disadvantages, but when it comes to deciding which one is best for your project, it’s important to understand the differences between them.
Sheet metal forming involves manufacturing processes in which the shaping is carried out without changing the mass, volume and material composition. However, forming changes the surface and properties of the metals to be machined. The process involves clamping the ends of rolled metal sheet (usually thinner than 6 mm) and then stretching over a forming block to the desired shape.
Multi-body plastic deformation problems are hot issues in metal forming simulation. AFDEX started to be applied for several multi-body forming processes since last year. AFDEX V19 has experienced more complicated and actual processes than before. Fig. shows elastoplastic FE predictions of a forming process for assembling three parts. The comparison between 2D results and 3D ones shows good similarity.