5R26. Metal Forming Analysis. - RH Wagoner (Dept of Mat Sci and Eng, Ohio State Univ, Columbus OH) and J-L Chenot (Mat Forming Center, Ecole des Mines, Paris, France). Cambridge UP, New York. 2001. 376 pp. ISBN 0-521-64267-1. $95.00.
Reviewed by WA Knight (Dept Indust and Manuf Eng, Univ of Rhode Island, Gilbreth Hall, Kingston RI 02881).
This work is a comprehensive presentation of the underlying principles and applications of the finite element method to the numerical simulation of both sheet and bulk metal forming processes. In this sense, the title is somewhat misleading as it implies a discussion of metal forming analysis in general, whereas very little is included on the more traditional approaches to metal forming analysis. However, the text is aimed at advanced graduate students and experienced practitioners in industry and elsewhere, who should be already familiar with the physical principles and equations for a basic understanding of metal deformation.
The material in the book is clearly presented, with numerous figures and illustrations that are of high quality. A comprehensive index is included at the end of the text. The first seven chapters are essentially introductory and cover the underlying principles and formulations of the finite element method applied to plasticity analysis. The authors follow a logical step-by-step approach to introducing these principles. Chapter 1 covers basic mathematical principles and a brief review of the mechanical principles of plasticity. In Chapter 2, the finite element method is introduced, and in Chapter 3, the specific extension to large deformation analysis is presented. Chapters 4 and 5 extend the discussion to typical finite element types and classification of finite element formulations. Chapter 6 is devoted to problems of boundary conditions in finite element analysis, including friction and contact between the deforming material and the tools or dies used. The introductory part of the book concludes with discussion of basic thermomechanical principles necessary for the analysis of temperature effects in metal deformation.
The remaining five chapters cover the application of finite element analysis to various types of metal forming. The results of case studies are used throughout to effectively illustrate the approach and the extensive data that can be generated from finite element simulations of the various forming processes. Chapter 8 covers sheet metal formability tests and their simulation. The next two chapters deal with bulk forming processes, with Chapter 9 devoted to steady state processes such as rolling, extrusion, and drawing, while Chapter 10 covers sheet metal forming applications. The final chapter of the book discusses some recent research topics including problems of meshing and remeshing, error estimation, and applications in the numerical modeling of orthogonal machining.
In general, the authors achieve their basic aim of providing a state-of-the-art presentation of the numerical methods for simulating forming operations for advanced graduate students and others utilizing these methods in industry and elsewhere. Metal Forming Analysis is an excellent textbook for advanced metal forming analysis courses. Most chapters include a problems section at the end. These problems are conveniently divided into proficiency, depth, and numerical problems. Computer packages based on the principles described in the book have become quite widely used in industry and research laboratories for the simulation and design of forming operations. This book is an excellent reference text for personnel using such packages, who need in depth information on the principles behind these programs. The results of numerical simulations have become accepted as accurate predictions of deformation, temperature, and so on. Perhaps the main thing missing in the text is appropriate experimental results to confirm the accuracy of the numerical predictions or to illustrate any inadequacies of simulations. This is particularly the case for the applications to bulk forming processes described.