OXFORD SERIES ON ADVANCED MANUFACTURING Metal Forming and. the Finite-Element MethodOXFORD SERIES ON ADVANCED MANUFACTURING METAL FORMING AND THE FINITE-ELEMENT METHOD SERIES EDITORS J. R. CROOKALL MILTON C. SHAW SHIRO KOBAYASHI 1, William T. Harris, Chemical Milling: the Technology of Ct SOOIK OH liam T. Harris, Chemical Milling: the Technology of Cuttin Materials by Etching (1976) “e a 8 TAYLAN ALTAN 2. Bernard Crossland. Explosive Welding of Metals and its Applications (1982) 3. Milton C. Shaw. Metal Cutting Principles (1984) 4. Shiro Kobayashi, Soo-Ik Oh, Taylan Altan. Metal Forming and the Finite-Element Method (1989) New York Oxford OXFORD UNIVERSITY PRESS 1989Oxford University Press Oxford New York “Toronto Delhi Bombay Calta Madias Kacch Petaling Jaya Singapore Hong Kong Takso [Nao Darr Salaam Cape Town Melboure Auckland nd ssocited companies in Beta Toad Copyright © 1989 by Oxford University Press, Inc Published by Oxford Universiy Press, in 200 Madson Avenue, New York, New York i016 (Oxford in repstered trademark of Oxo University Press All sights reseed. No pat ofthis publication maybe reproduce, ‘ore ina ttrival stem. o tasted, ina for oe By soy aa lectroni mechani, photocopying, recording, or ethers, ‘without the prior prison of Oxord Univesity Press Library of Congress C3 ging i Pabiation Data Kotayah, Shiv, Metal forming andthe ite lemont method / ‘Shiro Kobayas, Soo-k Oh, Taylan Alam cin. ~ (Oxford seis on tance manufotring: 4) Bibogaphy: Inches inde ISBN O19 sea 1. Meta woek—Matematieal mele Fine clement thos 1 Ob, Sook. Ahan. Tay. ML Te WV Sei, "TS2i3.K56 1m) ora de9e.4109s ce 135794642 Printed inthe United States of America fon sire paper PREFACE The application of computer-aided engineering, design, and manufactur- ing, CAE/CAD/CAM, is essential in modern metal-forming technology. Thus, process modeling for the investigation and understanding of deformation mechanics has become a major concern in research, and the finite-element method (FEM) has assumed increased importance, particu- larly in the modeling of forming processes. ‘There are many excellent textbooks on the principles and fundamentals ‘of metal forming, but only a few describe the application of FEM to the analysis and simulation of metal-forming processes. ‘The main purpose of this book is to present the fundamentals and applications of FEM in metal-forming analysis and technology. The book is primarily written for graduate students and researchers. However, it should also be useful to practicing engineers who have a good background in FEM and who are interested in applying this technique to the analysis of metal-deformation processes. In the application of FEM to metal forming, there are two formulations, namely, flow formulation and solid formulation. Flow formulation assumes that the deforming material has a negligible elastic response, while solid formulation includes elasticity. Despite recent advances, the application of solid formulation to the analysis of metal-forming problems remains limited. On the other hand, flow formulation has found applications in a wide variety of important forming problems. This book, therefore, is mainly devoted to the applications that are based on flow formulation (purely plastic and viscoplastic). However, recent advances achieved in Solid formulation have made it applicable to the analysis of some forming Problems. In crder not to neglect these investigations, comparisons of solutions ‘based on both formulations, solid and flow, are presented in Chapter 16. The book begins with a general background on the subject in Chapter 1 The description of metal-forming processes is given in Chapter 2, and Chapter 3 details important technological aspects of these processes, Chapters 4 and 5 present the theory of plasticity and methods of analysis as applied to metal forming. The FEM formulations are described in Chapters 6 and 7, and the applications of the method to the analyses of Various forming processes are presented in Chapters 8 through 11. Chapter