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Application of Metal Forming in Manufacturing Engineering

Application of Metal Forming in Manufacturing Engineering

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Application of Metal Forming in Manufacturing Engineering

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  1. Application of Metal Forming in Manufacturing Engineering Jenn-Terng Gau, Ph.D. Assistant Professor of Mechanical Engineering Northern Illinois University

  2. Metal Forming Research Sheet Metal Forming Micro-Forming Bulk Metal Forming Deep Drawing Stamping Sheet Bulk Forging Extrusion Research Interests

  3. Importance of Metal Forming in Manufacturing Engineering • Net Shape or Close to Net Shape • High Production Rate • High Profit Margin • Low Scrap Rate • Improving Material Properties • Etc.

  4. Applications and Products of Metal forming in Macro Scale • Automotive • Aerospace • Appliance • Cookware • Etc.

  5. Current Issues of Metal Forming Industry • Lack of Experienced Metal Forming Engineer • Short Product Life Cycle • New Metallic Materials • Developing New Hybrid Process • High Accuracy and Small Feature Products • Etc.

  6. OVERVIEW OF METAL FORMING • Bulk Deformation Processes: • Compressive deformation force • Significant deformations • Massive shape changes • Starting work shapes include billets and rectangular bars • Sheet metal working: • Also called “Pressworking” • Cold working processes • Use set of punch and die • Performed on metal sheets, strips and coils Surface Area / Volume is small Surface Area / Volume is large

  7. Metal Forming Processes Cup Drawing Rolling Forging Bending Shearing Wire Drawing Extrusion Sheet Metal Working Bulk Deformation Processes

  8. Examples of PrecisionCold Forged Products

  9. Precision Hot Forging of Complex Shapes

  10. Precision Hot Forging of Complex Shapes

  11. Sheet Metal Forming Stamping and Deep Drawing

  12. Product & Process CAE Die Design (CAD) Draw Dev. (CAD) Production Soft & hard Tool Tryout Machining CAM Stamping Process Flow in Automotive Industry

  13. Binder Wrap Simulation (CAE)

  14. R140 R140 Forming Simulation (CAE)

  15. Step widen (25mm from trim line) Radius enlarge Design „banana“ softer Optimize bulge Optimize the cape Optimize blank and draw bead R10 R180 R180 Reduce height of surface in this area Lift up surface Product Change and Draw Development Modification

  16. R180 R180 Rerun Forming Simulation

  17. Simulation with Autoform V2.1 CAE and Tryout Comparison

  18. Simulation with Autoform V2.1 CAE and Tryout Comparison

  19. Micro Metal Forming Sheet and bulk metals

  20. Applications and Products of Micro Forming • Cellular Telephones • IC Leadframes • Electronics • Healthcare • Miniature Fasteners • Hard Disc Drives • National Security & Defense • Automobiles • Sensors • Etc.

  21. STEPPER MOTOR 14.00” ISOMETRIC VIEW LOAD CELL TOP VIEW LVDT 6.75” SIZE OF MACHINE: 14.00” X 12.00” X 6.75” (SHOWN WITH DEEP DRAWING TOOL KIT) RIGHT VIEW Finished Micro Press Design

  22. NIU Micro Dies

  23. Skills Needed for Metal Forming Engineering • Mechanics • Material Science • Manufacturing Process • Design and Control • Machinery • Computer Skills • FEA

  24. Students Need • To know the current and future needs of metal forming industry. • To be taught on a series of classes to meet challenges of current and future metal forming industry.

  25. UEET 101 Problem Domain • According to your imagination, what is the best process to make beverage can?

  26. Homework • Is metal forming the most cost effective manufacturing process? • Why metal forming is the best process for mass production?