Innovations in manufacturing

<p>Foreword xvii</p> <p>List of Contributors xix</p> <p>Part I Advanced Forming Processes 1</p> <p><b>1 Advances in Stamping 3<br /> </b><i>Ilyas Kacar and Fahrettin Ozturk</i></p> <p>1.1 Introduction 3</p> <p>References 13</p> <p><b>2 Hydroforming 15<br /> </b><i>C Hartl</i></p> <p>2.1 Introduction 15</p> <p>2.2 Fundamentals 16</p> <p>2.3 Process Development and Design 33</p> <p>2.4 Hydroforming Systems 37</p> <p>2.5 Concluding Remarks 39</p> <p>References 40</p> <p><b>3 Incremental Sheet Forming 47<br /> </b><i>Rogelio Perez‐Santiago, Isabel Bagudanch, and Maria Luisa Garcia‐Romeu</i></p> <p>3.1 Incremental Sheet Forming: General Overview 47</p> <p>3.2 ISF Variants 49</p> <p>3.3 Process Cycle 51</p> <p>3.4 Materials 52</p> <p>3.5 Formability in ISF 52</p> <p>3.6 ISF Process Parameters 55</p> <p>3.7 Accuracy 55</p> <p>3.8 Simulation 57</p> <p>3.9 Future Trends in ISF 58</p> <p>3.10 Case Study 59</p> <p>3.11 Concluding Remarks 59</p> <p>References 60</p> <p><b>4 Powder Forming 65<br /> </b><i>Rahmi Unal</i></p> <p>4.1 Introduction 65</p> <p>4.2 Reasons for Using PM Route 67</p> <p>4.3 Powder Production 69</p> <p>4.4 Consolidation Techniques 73</p> <p>4.5 Sintering 79</p> <p>4.6 Powder Injection Molding (PIM) 82</p> <p>4.7 Summary and Future Work 84</p> <p>References 85</p> <p><b>5 Injection Molding at Multiscales 89<br /> </b><i>Danyang Zhao, Minjie Wang, and Donggang Yao</i></p> <p>5.1 Introduction 89</p> <p>5.2 Overview of Injection Molding 91</p> <p>5.3 Injection Molding of Precision Parts 105</p> <p>5.4 Injection Molding of Thin Wall Parts 109</p> <p>5.5 Injection Molding of Microstructured Parts 116</p> <p>5.6 Injection Molding of Microparts 124</p> <p>5.7 Simulation of Injection Molding 127</p> <p>5.8 Summary and Outlook 131</p> <p>References 132</p> <p><b>6 Manufacturing Techniques of Bulk Metallic Glasses 137<br /> </b><i>Mustafa Bakkal, Umut Karaguzel, and Ali T. Kuzu</i></p> <p>6.1 Introduction 137</p> <p>6.2 Mechanical Properties and Usage of Bulk Metallic Glasses 139</p> <p>6.3 Rapid Quenching Methods 140</p> <p>6.4 Water‐Quenching Method 141</p> <p>6.5 Arc Melting Drop/Suction Casting Method 142</p> <p>6.6 High‐Pressure Die Casting Method 143</p> <p>6.7 Copper Mold Casting Method 144</p> <p>6.8 Cap Casting Method 144</p> <p>6.9 Centrifugal Casting Method 145</p> <p>6.10 Metal Foaming Method 146</p> <p>6.11 Concluding Remarks 147</p> <p>References 147</p> <p><b>7 Micromanufacturing 149<br /> </b><i>Omer N. Cora and Muammer Koc</i></p> <p>7.1 Introduction 149</p> <p>7.2 Classification of Micromanufacturing Processes 150</p> <p>7.3 Micromanufacturing Processes 154</p> <p>References 179</p> <p><b>Part II Thermal and Energy‐assisted Manufacturing Processes 185</b></p> <p><b>8 Warm Stamping 187<br /> </b><i>Fahrettin Ozturk , Serkan Toros, and Ilyas Kacar</i></p> <p>8.1 What is Stamping? 187</p> <p>8.2 Benefits and Usage Areas of Warm Stamping 187</p> <p>8.3 Warm Stamping and Recent Developments 188</p> <p>8.4 Effects of Temperature on Strain Hardening for Warm Stamping 194</p> <p>8.5 Interrelation of Temperature and Strain Rate 196</p> <p>8.6 Effect of Temperature and Deformation on Elasticity Modulus 198</p> <p>8.7 Effect of Temperature on Springback 201</p> <p>8.8 Effect of Temperature on Forming Limit Diagrams (FLD) 204</p> <p>8.9 Analyze Techniques on Formability at Warm Stamping 205</p> <p>8.10 The Effects of Lubrication 215</p> <p>8.11 Future Directions 215</p> <p>References 216</p> <p><b>9 Warm Hydroforming 219<br /> </b><i>Muammer Koc, Omer N. Cora, Huseyin S. Halkacı, and Mevlut Turkoz</i></p> <p>9.1 Introduction 219</p> <p>9.2 Warm Sheet Hydroforming 220</p> <p>9.3 Warm Hydromechanical Deep Drawing 230</p> <p>9.4 Warm Tube Hydroforming 231</p> <p>References 237</p> <p><b>10 Hot Stamping 239<br /> </b><i>Fahrettin Ozturk , Ilyas Kacar, and Muammer Koc</i></p> <p>10.1 Introduction 239</p> <p>10.2 Process Description and Motivation 240</p> <p>10.3 Why Hot Stamping? 241</p> <p>10.4 Automotive Parts by Hot Stamping and Potentials 241</p> <p>10.5 Advantages and Disadvantages 243</p> <p>10.6 Process Description and Methods 245</p> <p>10.7 Cooling for Hot Stamping 254</p> <p>10.8 Process Control 255</p> <p>10.9 Modeling and Analysis 255</p> <p>10.10 Design and Optimization in Hot Stamping 256</p> <p>10.11 FEA in Hot Stamping 257</p> <p>10.12 Research and Development Trends and Needs 258</p> <p>References 262</p> <p><b>11 High‐Speed Forming (Electromagnetic, Electrohydraulic, and Explosive Forming) 265<br /> </b><i>Brad Kinsey and Yannis Korkolis</i></p> <p>11.1 Introduction 265</p> <p>11.2 Electromagnetic Forming and Magnetic Pulsed Welding 267</p> <p>11.3 Electrohydraulic Forming 274</p> <p>11.4 Explosive Forming 279</p> <p>11.5 Emerging Technologies 282</p> <p>11.6 Metrology and Measurements 284</p> <p>11.7 Material Characterization 286</p> <p>11.8 Modeling of High‐Speed Forming Processes 288</p> <p>11.9 Summary and Future Work 291</p> <p>References 292</p> <p><b>Part III Advanced Material Remov