Application of Metal Forming in Manufacturing Engineering Jenn-Terng Gau, Ph.D. Assistant Professor of Mechanical Engineering Northern Illinois University Research Interests Metal Forming Research Sheet Metal Forming Deep Drawing Stamping Micro-Forming Sheet Bulk Bulk Metal Forming Forging Extrusion Importance of Metal Forming in Manufacturing Engineering вЂў вЂў вЂў вЂў вЂў вЂў Net Shape or Close to Net Shape High Production Rate High Profit Margin Low Scrap Rate Improving Material Properties Etc. Applications and Products of Metal forming in Macro Scale вЂў вЂў вЂў вЂў вЂў Automotive Aerospace Appliance Cookware Etc. Current Issues of Metal Forming Industry вЂў Lack of Experienced Metal Forming Engineer вЂў Short Product Life Cycle вЂў New Metallic Materials вЂў Developing New Hybrid Process вЂў High Accuracy and Small Feature Products вЂў Etc. OVERVIEW OF METAL FORMING Surface Area / Volume is small Surface Area / Volume is large вЂў - Bulk Deformation Processes: Compressive deformation force Significant deformations Massive shape changes Starting work shapes include billets and rectangular bars вЂў - Sheet metal working: Also called вЂњPressworkingвЂќ Cold working processes Use set of punch and die Performed on metal sheets, strips and coils Metal Forming Processes Rolling Forging Extrusion Wire Drawing Bulk Deformation Processes Cup Drawing Bending Shearing Sheet Metal Working Examples of Precision Cold Forged Products Precision Hot Forging of Complex Shapes Precision Hot Forging of Complex Shapes Sheet Metal Forming Stamping and Deep Drawing Stamping Process Flow in Automotive Industry Product & Process Production Draw Dev. (CAD) Soft & hard Tool Tryout CAE Machining Die Design (CAD) CAM Binder Wrap Simulation (CAE) Forming Simulation (CAE) Product Change and Draw Development Modification Step widen (25mm from trim line) Radius enlarge Design вЂћbananaвЂњ softer Optimize bulge Optimize the cape Optimize blank and draw bead R10 Lift up surface Reduce height of surface in this area Rerun Forming Simulation CAE and Tryout Comparison Simulation with Autoform V2.1 CAE and Tryout Comparison Simulation with Autoform V2.1 Micro Metal Forming Sheet and bulk metals Applications and Products of Micro Forming вЂў вЂў вЂў вЂў вЂў вЂў вЂў Cellular Telephones IC Leadframes Electronics Healthcare Miniature Fasteners Hard Disc Drives National Security & Defense вЂў Automobiles вЂў Sensors вЂў Etc. Finished Micro Press Design STEPPER MOTOR 14.00вЂќ ISOMETRIC VIEW LOAD CELL TOP VIEW LVDT 6.75вЂќ SIZE OF MACHINE: 14.00вЂќ X 12.00вЂќ X 6.75вЂќ (SHOWN WITH DEEP DRAWING TOOL KIT) RIGHT VIEW NIU Micro Dies Skills Needed for Metal Forming Engineering вЂў вЂў вЂў вЂў вЂў вЂў вЂў Mechanics Material Science Manufacturing Process Design and Control Machinery Computer Skills FEA Students Need вЂў To know the current and future needs of metal forming industry. вЂў To be taught on a series of classes to meet challenges of current and future metal forming industry. UEET 101 Problem Domain вЂў According to your imagination, what is the best process to make beverage can? Homework вЂў вЂў Is metal forming the most cost effective manufacturing process? Why metal forming is the best process for mass production?