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Dealing with forming and tinning in a low‐volume high‐reliability environment is a never‐ending challenge. This process is one of the most critical steps in SMT fabrication. The effects of forming and tinning contribute to a majority of the defects found at final inspection. The intention of this paper is to describe in detail the forming and tinning process and all that it entails. The topics include: forming, tinning, converting to an automated process, process control techniques, and statistical process capability.

To study the influence of process and product parameters on the properties of products in incremental sheet metal‐forming; to create models for process optimisation and to introduce an approach to incremental forming process optimisation.

A new flexible sheet metal‐forming technique, incremental forming, has been studied. The technique can be viewed as a rapid prototyping/manufacturing technique for sheet metal parts. To analyse the process, an experimental study and finite element analysis were performed. For the optimal design of incremental forming process non‐linear mathematical programming was used. To estimate the limitations and main parameters of the process, a complex model was developed.

Introducing optimisation procedures for the incremental forming process allows users to increase productivity and to assure quality.

As finite element analysis of the process is time‐consuming in real life situations, a future study should include creating analytical models for process modelling.

The described approach can be used in practice to improve competitiveness of companies producing sheet metal prototypes.

This paper offers guidelines for shortening processing time of sheet metal prototypes for engineers and researchers. The optimisation that is based on experimental/theoretical/numerical models of incremental forming process has not been covered before in the scientific literature.

This paper aims to introduce a new incremental sheet metal‐forming process. By moving a hammering tool over a sheet of metal fixed in a frame, a three‐dimensional workpiece can be produced without using any special die plate.

This paper describes the exact procedure of the new process and the advantages in comparison with other flexible conventional and incremental forming processes. The hammering process in particular, will be considered with respect to material behavior and effects on the industrial robot. In addition, a special path generation for the incremental forming process and multiple robot tools with different drives constructed for the incremental forming process is shown.

During the research it was discovered that complex geometries can be produced without any die plate and that a hammering tool with a mechanical eccentric should be used for the incremental forming process.

As the forces on the handling equipment are very low compared with other forming processes, a common industrial robot can be used to move the hammering tool. Thus sheet metal parts can be produced with cost‐effective equipment. Mainly, small and medium‐sized enterprises can benefit from this new technology.

The incremental forming process presented in this paper is patented by the Fraunhofer Institute for Manufacturing Engineering and Automation. It is the first time that sheet metal parts with a size of 300×300 mm are formed by a hammering tool with 100 hits/s.

Aerospace industry was pioneered in the use of superplastic forming (SPF) process. Weight saving is the most important need in this industry. For this reason, there is special attention paid to this method. Blow forming is a common method for SPF process. Process parameters such as temperature and pressure have significant effects on part accuracy, quality and desired characteristics. The purpose of this paper is to present a numerical and experimental investigation of process parameters in superplastic free bulge forming.

In this paper, superplastic free bulge forming of Al‐5083 has been studied. First, free bulge tests have been done at two different pressures. Bulge height variations were recorded for different pressure and temperature. The forming time was determined according to the forming pressure and temperature. Then, simulation of free bulge process has been carried out using creep behavior model at high temperature. Bulge height and thickness distribution are obtained at two different pressure settings. These results have been compared with experimental results presenting a good agreement. Also the effects of temperatures and pressure on the required process time are compared for a certain bulge height. Finally, thickness distribution profile for different temperatures, pressures and initial thicknesses have been studied.

A numerical and experimental investigation has been presented that can be used to study the process parameters. These findings show the effects of temperatures, pressure and initial thicknesses on sheet forming.

The results of this work show that higher temperature and forming pressure will reduce the required process time for a certain bulge height. Reduction of these parameters can improve thickness distribution. Also, by considering the effects of both pressure and temperature, it is shown that using lower forming pressure at higher temperature is more suitable for forming. The findings of this work can provide more understanding of the process for aircraft part designers and manufacturing process planners.

Sheet metal forming is a process of shaping thin sheets of metal by applying pressure through male or female dies or both. In most of used sheet‐formating processes the metal is subjected to primarily tensile or compressive stresses or both. During the last three decades considerable advances have been made in the applications of numerical techniques, especially the finite element methods, to analyze physical phenomena in the field of structural, solid and fluid mechanics as well as to simulate various processes in engineering. These methods are useful because one can use them to find out facts or study the processes in a way that no other tool can accomplish. Finite element methods applied to sheet metal forming are the subjects of this paper. The reason for writing this bibliography is to save time for readers looking for information dealing with sheet metal forming, not having an access to large databases or willingness to spend own time with uncertain information retrieval. This paper is organized into two parts. In the first one, each topic is handled and current trends in the application of finite element techniques are briefly mentioned. The second part, an Appendix, lists papers published in the open literature. More than 900 references to papers, conference proceedings and theses/dissertations dealing with subjects that were published in 1995‐2003 are listed.

The purpose of this paper is to explore the basic loading state in local loading forming process of large-sized complicated rib-web component, which is important for understanding process characteristic, controlling metal flow and designing preformed geometry of the local loading forming process. Moreover the analytical models for different loading states are established to quickly predict the metal flow.

Through analysis of geometric characteristic of large-sized complicated rib-web component and the deformation characteristic on planes of metal flow by local loading method, a representative cross-section is put forward and designed, which could reflect the local loading forming characteristics of large-sized complicated rib-web component. Finite element method (FEM) is used to analyze the stress and metal flow, and the analytical models of metal flow are established by using slab method (SM).

Three local loading states and one whole loading state are found in the local loading forming process of representative cross-section. Further, four loading states also exist in local loading forming process of large-sized complicated rib-web components. With the metal distribution in the process, some local loading states may turn into whole loading state. For the representative cross-section, the relative error of metal distribution between SM and FEM results is less than 15 per cent, and the relative error of metal in the rib cavity between SM and FEM results is less than 10 per cent.

Metal flow can be controlled by adjusting the loading states in the process. According to the metal flow laws in different loading states, a simple unequal-thickness billet can be designed to achieve initial metal distribution, and then, the secondary metal distribution can be achieved in the process.

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming, powder metallurgy and composite material processing are briefly discussed. The range of applications of finite elements on these subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE researchers/users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for 1994‐1996, where 1,370 references are listed. This bibliography is an updating of the paper written by Brannberg and Mackerle which has been published in Engineering Computations, Vol. 11 No. 5, 1994, pp. 413‐55.

To provide a selective bibliography for researchers working with bulk material forming (specifically the forging, rolling, extrusion and drawing processes) with sources which can help them to be up‐to‐date.

A range of published (1996‐2005) works, which aims to provide theoretical as well as practical information on the material processing namely bulk material forming. Bulk deformation processes used in practice change the shape of the workpiece by plastic deformations under forces applied by tools and dies.

Provides information about each source, indicating what can be found there. Listed references contain journal papers, conference proceedings and theses/dissertations on the subject.

It is an exhaustive list of papers (1,693 references are listed) but some papers may be omitted. The emphasis is to present papers written in English language. Sheet material forming processes are not included.

A very useful source of information for theoretical and practical researchers in computational material forming as well as in academia or for those who have recently obtained a position in this field.

There are not many bibliographies published in this field of engineering. This paper offers help to experts and individuals interested in computational analyses and simulations of material forming processes.

There are process uncertainties and material property variations during laminated steel sheet forming, and those fluctuations may result in non-reliable forming quality issues such as fracture and delamination. Additionally, the optimization of sheet forming process is a typical multi-objective optimization problem. The target is to find a multi-objective design optimization and improve the process design reliability for laminated sheet metal forming. The paper aims to discuss these issues.

Desirability function approach is adopted to conduct deterministic multi-objective optimization, and response surface is used as meta-model. Reliability analysis is conducted to evaluate the robustness of the multi-objective design optimization. The proposed method is implemented in a step-bottom square cup drawing process. First, forming process parameters and three noise factors are assumed as probability variables to conduct reliability assessment of the laminated steel sheet forming process using Monte Carlo simulation. Next, only two forming process parameters, blank holding force and frictional coefficient, are considered as probability variables to investigate the influence of the forming parameter deviation on the variance of the response using the first-order second-moment method.

The results indicate that multi-objective design optimization using desirability function method has high efficiency, and an optimized robust design can be obtained after reliability assessment.

The proposed design procedure has potential as a simple and practical approach in the laminated steel sheet forming process.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.