Computer Applications in Near Net-Shape Operations

Addresses the design, analysis and simulation of near net-shape operations using some of the most advanced computer techniques/tools available. The text covers topics such as sheet metal forming operations; die design, construction and NC programming of wire EDM; and bulk metal forming processes.

1 Introduction to near net-shape operations.- 1.1 Introduction.- 1.2 Classification of near net-shape operations.- 1.2.1 Sheet metal forming.- 1.2.2 Massive (bulk) metal forming processes.- 1.2.3 Injection moulding.- 1.2.4 Machines for near net-shape operations.- 1.3 Near net-shape operations: past, present and future.- 2 CAD/CAM for sheet metal forming and related processes.- 2.1 Introduction and basic techniques.- 2.1.1 Feature modelling of stampings.- 2.1.2 Application of expert systems to stamping die design.- 2.2 Optimisation of blank layout.- 2.2.1 Mathematical description of blank layout.- 2.2.2 The polygon method.- 2.2.3 The height function method.- 2.3 Fine blanking.- 2.3.1 Characteristics of the fine blanking process.- 2.3.2 Application of the fine blanking process.- 2.3.3 CAD/CAM of fine blanking dies.- 2.4 Progressive stamping.- 2.4.1 Software architecture of the system.- 2.4.2 Strip layout.- 2.4.3 Construction design of progressive dies.- 2.5 An overview of a flat patterning and bending simulation system.- 2.5.1 Design input module.- 2.5.2 Flat pattern development module.- 2.5.3 Bending simulation module.- 2.5.4 System details.- 2.5.5 Implementation of bending simulation module.- 2.6 CNC punching and nibbling.- 2.6.1 Computer-based system for CNC nibbling.- 2.6.2 Punch libraries.- 2.6.3 Profile classification.- 2.6.4 Punch selection and optimisation.- 2.6.5 An approach to automatic tool selection.- 2.6.6 A case study.- 2.7 Die construction design.- 2.7.1 Design of die and punch.- 2.7.2 Layout of ejectors.- 2.8 NC programming of wire EDM.- 2.8.1 Process consideration for NC programming of wire EDM.- 2.8.2 Geometric computation.- 2.8.3 NC programming procedure for wire EDM.- References.- 3 CAD/CAM for massive (bulk) metal forming.- 3.1 Introduction.- 3.2 Cold upsetting.- 3.2.1 Determination of operations and sequences.- 3.2.2 Calculation of process parameters.- 3.2.3 Design of dies cavities, general parts and combined dies.- 3.2.4 The BNC CAD system.- 3.3 Closed-die forging.- 3.3.1 Selection and calculation of bars.- 3.3.2 Determination of operations and sequences.- 3.3.3 Calculation of forging load and stress.- 3.3.4 Design of dies.- 3.3.5 Program flowchart and description.- References.- 4 CAD/CAE/CAM for injection moulding.- 4.1 Introduction.- 4.1.1 Brief history of development.- 4.1.2 Technological characteristics.- 4.2 Graphic input and geometry construction of injection moulded products.- 4.2.1 Wire-frame modelling.- 4.2.2 Surface modelling.- 4.2.3 Solid modelling.- 4.3 CAD for construction design of plastic injection moulds.- 4.3.1 Program flowchart.- 4.3.2 Standard mould base design.- 4.3.3 Cavity and core design.- 4.3.4 Runner bar design.- 4.4 Flow simulation of plastic injection moulding.- 4.4.1 One-dimensional flow analysis.- 4.4.2 Two-dimensional flow analysis.- 4.4.3 Three-dimensional flow analysis.- 4.5 Cooling simulation of plastic injection moulding.- 4.5.1 One-dimensional cooling analysis.- 4.5.2 Two-dimensional cooling analysis.- 4.5.3 Three-dimensional cooling analysis.- 4.6 CAM for plastic injection moulds.- 4.6.1 Integrated CAD/CAM system.- 4.6.2 Information transfer from CAD to CAM.- 4.6.3 Tool path generation in 2-D NC.- 4.6.4 Manufacturing for 3-D core and cavity.- 4.7 CAD/CAE/CAM system for plastic injection moulding.- 4.7.1 System configuration.- 4.7.2 CAD software functions.- 4.7.3 CAE software functions.- 4.7.4 CAM software functions.- 5 FEM applications in near net-shape operations.- 5.1 Introduction.- 5.2 FEM applications and developments in near net-shape operations.- 5.2.1 New algorithms for automatic triangular mesh generation.- 5.2.2 New algorithms for mesh rezoning in FEM simulation.- 5.2.3 Algorithms for generating isogram in FEM.- 5.2.4 Calculation of rigid regions using rigid-plastic FEM.- 5.3 FEM applications in massive (bulk) metal forming processes.- 5.3.1 Simulation of rigid-plastic finite element of radial extrusion process.- 5.3.2 Rigid-plastic finite element simulation ...