Modeling of Metal Forming and Machining Processes (eBook)

Prof. P. M. Dixit has been actively working in the area of metal forming, machining and non-traditional machining for the past 20 years. He has published extensively in leading international journals and carried out projects in the area of metal forming and large deformation. He also teaches Metal Forming, Plasticity and FEM to postgraduate and senior undergraduate students. Prof. P.M. Dixit obtained his bachelors degree in Aeronautical Engineering from the Indian Institute of Technology, Kharagpur, in 1974. He was awarded a silver medal for securing the first rank in the Department. Subsequently, he obtained his doctoral degree in Mechanics from the University of Minnesota, Minneapolis, U.S.A, in 1979. After receiving his Ph.D. degree, Prof. Dixit taught at the Aeronautical Engineering Department of the Indian Institute of Technology, Kharagpur for 4 years (1980-1984). Since 1984, Prof. Dixit has been teaching at the Mechanical Engineering Department of the Indian Institute of Technology, Kanpur. Prof. U. S. Dixit has more than a decade’s experience in carrying out research in the area of metal forming and machining. Apart from FEM, he uses fuzzy set theory and neural networks in his research. Before taking up a research career, he worked for four years as a machine tool designer in HMT Ltd. Pinjore, India. He has a number of publications, some of them jointly with Prof. P.M. Dixit. Prof. U. S. Dixit is currently a Professor of Mechanical Engineering at the Indian Institute of Technology in Guwahati. Prof. U. S. Dixit obtained his bachelors degree in Mechanical Engineering from the Indian Institute of Technology, Roorkee in 1987. He gained his M. Tech in Mechanical Engineering and his Ph.D. in Mechanical Engineering from the Indian Institute of Technology, Kanpur, in 1993 and 1998 respectively.

Preface 7
Contents 11
1 Metal Forming and Machining Processes 17
1.1 Introduction 17
1.2 Metal Forming 18
1.3 Machining 39
1.4 Summary 47
1.5 References 47
2 Review of Stress, Linear Strain and Elastic Stress- Strain Relations 49
2.1 Introduction 49
2.2 Index Notation and Summation Convention 51
2.3 Stress 57
2.4 Deformation 80
2.5 Material Behavior 100
2.6 Summary 109
2.7 References 110
3 Classical Theory of Plasticity 111
3.1 Introduction 111
3.2 One-Dimensional Experimental Observations on Plasticity 113
3.3 Criteria for Initial Yielding of Isotropic Materials 123
3.4 Incremental Strain and Strain Rate Measures 137
3.5 Modeling of Isotropic Hardening or Criterion for Subsequent Isotropic Yielding 150
3.6 Plastic Stress-Strain and Stress-Strain Rate Relations for Isotropic Materials 157
3.7 Objective Stress Rate and Objective Incremental Stress Tensors 177
3.8 Unloading Criterion 184
3.9 Eulerian and Updated Lagrangian Formulations for Metal Forming Processes 186
3.10 Eulerian Formulation for Machining Processes 204
3.11 Summary 208
3.12 References 209
4 Plasticity of Finite Deformation and Anisotropic Materials, and Modeling of Fracture and Friction 211
4.1 Introduction 211
4.2 Kinematics of Finite Deformation and Rotation 213
4.3 Constitutive Equation for Eulerian Formulation When the Rotation Is Not Small 223
4.4 Kinematics of Finite Incremental Deformation and Rotation 228
4.5 Constitutive Equation for Updated Lagrangian Formulation for Finite Incremental Deformation and Rotation 235
4.6 Anisotropic Initial Yield Criteria 239
4.7 Elastic-Plastic Incremental Stress-Strain and Stress-Strain Rate Relations for Anisotropic Materials 255
4.8 Kinematic Hardening 263
4.9 Modeling of Ductile Fracture 268
4.10 Friction Models 281
4.11 Summary 284
4.12 References 285
5 Finite Element Modeling of Metal Forming Processes Using Eulerian Formulation 289
5.1 Introduction 289
5.2 Background of Finite Element Method 290
5.3 Formulation of Plane-Strain Metal Forming Processes 313
5.4 Formulation of Axisymmetric Metal Forming Processes 338
5.5 Formulation of Three-Dimensional Metal Forming Processes 347
5.6 Incorporation of Anisotropy 347
5.7 Elasto-Plastic Formulation 350
5.8 Summary 357
5.9 References 357
6 Finite Element Modeling of Metal Forming Processes Using Updated Lagrangian Formulation 361
6.1 Introduction 361
6.2 Application of Finite Element Method to Updated Lagrangian Formulation 363
6.3 Modeling of Axisymmetric Open Die Forging by Updated Lagrangian Finite Element Method 388
6.4 Modeling of Deep Drawing of Cylindrical Cups by Updated Lagrangian Finite Element Method 412
6.5 Summary 435
6.6 References 436
7 Finite Element Modeling of Orthogonal Machining Process 441
7.1 Introduction 441
7.2 Domain, Governing Equations and Boundary Conditions for Eulerian Formulation 442
7.3 Finite Element Formulation 447
7.4 Results and Discussion 458
7.5 Summary 463
8 Background on Soft Computing 467
8.1 Introduction 467
8.2 Neural Networks 468
8.3 Fuzzy Sets 488
8.4 Genetic Algorithms 507
8.5 Soft Computing vs FEM 514
8.6 Summary 515
8.7 References 516
9 Predictive Modeling of Metal Forming and Machining Processes Using Soft Computing 519
9.1 Introduction 519
9.2 Design of Experiments and Preliminary Study of the Data 520
9.3 Preliminary Statistical Analysis 524
9.4 Neural Network Modeling 538
9.5 Prediction of Dependent Variables Using Fuzzy Sets 549
9.6 Prediction Using ANFIS 551
9.7 Computation with Fuzzy Variables 555
9.8 Summary 561
9.9 References 562
10 Optimization of Metal Forming and Machining Processes 565
10.1 Introduction 565
10.2 Optimization Problems in Metal Forming 566
10.3 Optimization Problems in Machining 575
10.4 Summary 589
10.5 References 589
11 Epilogue 595
11.1 References 599
Index 601