Tecnologia de Enformação Plástica

Objectives

The course aims to provide advanced skills for the project and design of metal forming processes and tooling. Formability limits and the theoretical and experimental methods and procedures for its determination are comprehensively analysed. A user’s perspective on the main existing finite element formulations to analyse metal forming processes is given so that students can recognize the pitfalls of the existing formulations, identify the possible sources of errors and understand the routes for validating their numerical results. Special attention is paid to thermo-electric-mechanical coupling built upon the finite element flow formulation. The last part of the course is focused on the project and design of tools for bulk and sheet metal forming industrial processes taking into consideration the above-mentioned knowledge on formability limits and finite element modelling

Syllabus

1. Formability. Plastic instability and fracture. Ductile damage. Experimental characterization. Representation in principal strain space and in stress triaxiality space. 2. Numerical simulation of metal forming processes. User's perspective on quasi-static and dynamic formulations. Accuracy, reliability and validity of finite element computer programs for metal forming processes. 3. Finite element flow formulation. Variational principle. Thermo- electric-mechanical coupling. Constraints. Discretization. Computer implementation. 4. Project and design of tools for bulk metal forming processes (Forging. Extrusion. Drawing. Rolling) and sheet metal forming processes (Bending. Roll bending. Fluo turning. Deep drawing. Incremental sheet forming).

Prerequisites

Approval in Manufacturing Processes I or equivalent course.

Cross Competence Component

The work to be carried out includes the following soft skills: critical and innovative thinking, decision making, teamwork, leadership, written communication and oral communication, use of computer and multimedia tools, report structuring and presentation.

Laboratorial Component

1. Experimental formability tests. 2. Metal forming tests. 3. Finite element simulation of metal forming processes.

Programming And Computing Component

Utilization of finite element computer programs. Knowledge in estimating the required CPU time, memory and necessity of using parallel computation. Programming skills are required for the construction of interface programs between finite element programs, CAD systems and pre and post processors (search algorithms, sorting, exploration,insertion and query of structured data).

Ethical Principles

All members of a group are responsible for the group’s work In any assessment, every student shall honestly disclose any help received and sources used. In an oral assessment, every student shall be able to present and answer questions about the entire assignment and solution.