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

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Research Interests
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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.

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Applications and Products of Metal forming in
Macro Scale

• Automotive
• Aerospace
• Appliance
• Cookware
• Etc.

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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.

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OVERVIEW OF METAL FORMING

• 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

Surface Area / Volume is small
Surface Area / Volume is large
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Metal Forming Processes
Cup Drawing
Rolling
Forging
Bending
Shearing
Wire Drawing
Extrusion
Sheet Metal Working
Bulk Deformation Processes
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Examples of PrecisionCold Forged Products
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Precision Hot Forging of Complex Shapes
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Precision Hot Forging of Complex Shapes
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Sheet Metal Forming

• Stamping and Deep Drawing

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Importance of Stamping

• Stamping is an efficient and low cost process for
  high volume manufacturing.
• In automotive Industry, 70 of parts are formed
  by stamping process

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Stamping Process Flow in Automotive Industry
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Binder Wrap Simulation (CAE)
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Forming Simulation (CAE)
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Product Change and Draw Development Modification
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Rerun Forming Simulation
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CAE and Tryout Comparison
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CAE and Tryout Comparison
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Draw Die
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Micro Metal Forming

• Sheet and bulk metals

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Applications and Products of Micro Forming

• Cellular Telephones
• IC Leadframes
• Electronics
• Healthcare
• Miniature Fasteners
• Hard Disc Drives
• National Security Defense
• Automobiles
• Sensors
• Etc.

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Finished Micro Press Design
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NIU Micro Dies
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Skills Needed for Metal Forming Engineering

• Mechanics
• Material Science
• Manufacturing Process
• Design and Control
• Machinery
• Computer Skills
• FEA

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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.

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UEET 101 Problem Domain

• According to your imagination, what is the best
  process to make beverage can?

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Homework

• Is metal forming the most cost effective
  manufacturing process?
• Why metal forming is the best process for mass
  production?