Finite Element Method in Manufacturing

Nowadays, the finite element method (FEM) has become the main instrument for simulating manufacturing processes. It is made up of a complex process involving a variety of physical phenomena, such as plastic deformation, frictional contact, thermo-mechanical coupling, burr formation mechanisms, etc. Experimental approaches to study the manufacturing processes are important but they can be replaced by FEM analysis, especially when a wide range of parameters is involved such as process parameters, material of the workpiece and tool types. This book aims to provide some fundamentals on research advances on FEM applied in manufacturing processes such as machining, bulk deformation, sheet metal forming, surface treatments, micromanufacturing processes, etc. Useful as a research book for final undergraduate engineering courses (for example, mechanical, manufacturing, etc.) or as a subject on numerical methods at the postgraduate level, this book can also serve as a useful reference for academics, manufacturing researchers, mechanical and manufacturing engineers and professionals in relation to manufacturing and computational mechanics.

J. Paulo Davim is Aggregate Professor in the Department of Mechanical Engineering at the Univerrsity of Aveiro, Portugal and is Head of MACTRIB (Machining and Tribology Research Group). His main research interests include machining/manufacturing processes and tribology/surface engineering.

Preface	p. ix
Authentication of FEM in Metal Cutting	p. 1
Introduction	p. 2
What seems to be the problem?	p. 3
Practical use of metal cutting theories and the FEM	p. 4
Need for proper simulations in metal cutting	p. 5
FEM in metal cutting: issues that need to be addressed	p. 9
Clear objectives of FEM simulations	p. 9
Proper definition of the metal-cutting process and physically sound model	p. 11
Work material model	p. 15
Verification of the FEM in metal cutting	p. 31
Common sense verification	p. 33
Geometrical and metallographical similarities	p. 34
Deformation similarity	p. 36
Thermodynamic similarity	p. 39
Bibliography	p. 40
Finite Element Modeling of HSM with Coated Tools
Introduction	p. 46
Metal cutting'	p. 47
Orthogonal cutting model	p. 47
HSM	p. 48
Cutting tools and coatings	p. 51
Properties of hard coatings	p. 53
Restricted contact length	p. 55
Heat generation and distribution in machining	p. 59
Estimation of heat source on the rake face	p. 61
Finite element analysis (FEA) of the machining process	p. 62
Experimental details	p. 67
Temperature measurement	p. 68
FE transient heat transfer analysis	p. 70
Results and discussion	p. 73
Cutting forces	p. 73
Chip compression ratio	p. 74
Tool-chip contact area and phenomena	p. 75
Heat partition into the cutting tool	p. 78
Conclusions	p. 84
Bibliography	p. 85
Experimental and Numerical Modeling of Tube End-Forming Processes	p. 93
Introduction	p. 93
Theoretical background	p. 96
Cold forming of metals and polymers	p. 96
Extended finite element flow formulation	p. 98
Experimentation	p. 101
Stress-strain curve	p. 101
Density	p. 102
Critical instability load	p. 104
Mechanics of deformation	p. 105
Invert forming	p. 105
Expansion and reduction	p. 113
Compression beading and nosing	p. 117
End forming of PVC tubes	p. 120
Innovative applications	p. 126
Conclusions	p. 131
Bibliography	p. 133
Finite Element Modeling of Rolling Processes	p. 137
Introduction	p. 137
Background on the FEM	p. 140
Flow formulation of the cold rolling processes	p. 142
Updated Lagrangian formulation of cold rolling processes	p. 154
Formulation for hot rolling processes	p. 161
Heat transfer equations	p. 162
Material behavior	p. 164
Conclusions	p. 169
Bibliography	p. 169
Finite Element Modeling of Ball-Burnishing Surface Treatments	p. 173
Introduction	p. 173
Modeling of the ball-burnishing process	p. 177
Preliminary considerations	p. 179
Simulation of the ball movement	p. 183
Simulation results	p. 186
Model validation	p. 193
Experimental set up	p. 193
Results and discussion	p. 194
Summary and conclusions	p. 196
Acknowledgments	p. 197
Bibliography	p. 198
Combining the Finite Element Method and Artificial Intelligence in Manufacturing Modeling and Optimization	p. 201
Introduction	p. 201
A brief overview on AI techniques	p. 203
AI techniques for modeling	p. 203
AI techniques for optimizing	p. 211
Approaches for combining the FEM and AI in machining research	p. 214
Approaches for combining the FEM and AI in machining modeling	p. 214
Approaches for combining FEM and AI in machining optimization	p. 219
An application sample	p. 221
Problem definition	p. 221
Simulation	p. 223
Neural network-based modeling	p. 226
Genetic algorithm-based optimization	p. 230
Experimental validation	p. 235
Concluding remarks	p. 235
Bibliography	p. 236
List of Authors	p. 241
Index	p. 245
Table of Contents provided by Ingram. All Rights Reserved.

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Finite Element Method in Manufacturing Processes

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