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Application of Metal Forming in Manufacturing Engineering

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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
•
•
•
•
•
•
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
•
•
•
•
•
Automotive
Aerospace
Appliance
Cookware
Etc.
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.
OVERVIEW OF METAL FORMING
Surface Area
/ Volume
is small
Surface Area
/ Volume
is large
•
-
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
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 „banana“ 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
•
•
•
•
•
•
•
Cellular Telephones
IC Leadframes
Electronics
Healthcare
Miniature Fasteners
Hard Disc Drives
National Security &
Defense
• Automobiles
• Sensors
• Etc.
Finished
Micro
Press
Design
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
NIU Micro Dies
Skills Needed for Metal
Forming Engineering
•
•
•
•
•
•
•
Mechanics
Material Science
Manufacturing Process
Design and Control
Machinery
Computer Skills
FEA
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.
UEET 101 Problem Domain
• According to your imagination, what is the
best process to make beverage can?
Homework
•
•
Is metal forming the most cost effective manufacturing process?
Why metal forming is the best process for mass production?
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