Preface	7
	Acknowledgements	10
	Contents	11
	1 Introduction	14
	1.1 Introduction	14
	1.2 Plastic Deformation of Materials	15
	1.3 Forming Process	17
	1.3.1 Cold Forming	17
	1.3.2 Warm Forming	18
	1.3.3 Hot Forming	19
	1.4 Metal-Forming Process and System	20
	1.5 Challenges in Metal-Formed Product Development	21
	1.5.1 Multidomains Involved in Metal-Formed Product Development	23
	1.5.2 Design of the Deformed Parts	26
	1.5.3 Process and Process Parameter Configuration	28
	1.5.4 Die Design and Its Service Life Analysis	29
	1.5.5 Defect Formation, Prediction, and Avoidance	31
	1.5.6 Optimization of Metal-Forming System	32
	1.6 Summary	32
	References	33
	2 Rigid-Plastic Finite Element Method and FE Simulation	34
	2.1 Introduction	34
	2.2 Modeling and Simulation	36
	2.3 Rigid-Plastic Finite Element Method	37
	2.3.1 Cartesian Tensor Representation	37
	2.3.2 Basic of Rigid-Plastic Finite Element Method	42
	2.3.3 Finite Element Simulation	48
	2.4 FE Simulation of Metal-Forming Systems	51
	2.4.1 Modeling of Die and Workpiece	52
	2.4.2 Modeling of Frictional Behaviors	54
	2.5 Geometric Symmetry in FE Simulation	55
	2.6 Validation and Verification of FE Simulation	59
	2.7 Summary	62
	References	63
	3 Evaluation of Forming System Design	64
	3.1 Introduction	64
	3.2 Evaluation of Metal-Forming Systems	66
	3.2.1 Factors Affecting the Design of Metal-Forming Systems	66
	3.2.2 Design of Deformed Parts	70
	3.2.2.1 Experimental Realization of the Twelve Design Scenarios	73
	3.2.2.2 Simulation and Analysis of the Twelve Design Scenarios	74
	3.2.3 Process and Die Design	87
	3.2.4 Simulation-Aided Evaluation of Metal-Forming Systems	89
	3.3 Realization of CAE Simulation	90
	3.3.1 Simulation Procedure	91
	3.3.2 Integrated Simulation Framework	92
	3.4 Evaluation Methodology	94
	3.4.1 Deformation Load	95
	3.4.2 Effective Strain	95
	3.4.3 Damage Factor	96
	3.4.4 Maximum Effective Stress	97
	3.4.5 Deformation Homogeneity	98
	3.4.6 Evaluation Criterion	99
	3.5 Case Studies	100
	3.6 Summary	104
	References	105
	4 Die Design and Service Life Analysis	107
	4.1 Introduction	107
	4.2 Die Performance and Service Life	108
	4.3 Stress-Based Die Design	110
	4.3.1 Prestress in Design	111
	4.3.2 Die Working Stress	116
	4.4 Die Fatigue Life Analysis	120
	4.4.1 Stress-Life Approach	121
	4.4.2 Strain-Life Approach	122
	4.4.3 Die Fatigue Life Assessment	124
	4.5 Case Studies	126
	4.5.1 Case Study 1	127
	4.5.2 Case Study 2	128
	4.5.3 Case Study 3	130
	4.5.3.1 Design of Metal-Forming System	133
	4.5.3.2 Integrated Simulation of Forming System	133
	4.5.3.3 Procedure for Extraction of Simulation Results	136
	4.6 Summary	141
	References	141
	5 Flow-Induced Defects in Multiscaled Plastic Deformation	143
	5.1 Introduction	143
	5.2 Flow-Induced Defect in Forming Processes	144
	5.2.1 Flow-Induced Defect in Forming of Axisymmetric Parts with Flanged Features	147
	5.2.2 Flow-Induced Defect in Forming of Non-asymmetrically Mesoscaled Parts	150
	5.2.2.1 Mesoforming Experiment	150
	5.2.2.2 FE Simulation	155
	5.3 Defect Avoidance in Forming Process	157
	5.3.1 Employment of Spring-Driven Die Insert Structure	157
	5.3.1.1 Sliding Die Insert Design and Material Flow Behaviors	157
	5.3.1.2 Spring and Die Insert Design Aided by FE Simulation	163
	5.3.1.3 Case Studies for Folding Defect Avoidance	164
	5.3.2 Feature-Based Approach for Folding Defect Avoidance	166
	5.3.2.1 Feature-Based Approach	166
	5.3.2.2 Detailed Approaches to Avoiding the Flow-Induced Defects	169
	5.3.2.3 Physical Implementation of the Designed Forming Processes	171
	5.4 Flow-Induced Defect and Size Effect in Meso- and Microforming	175
	5.4.1 Experiments of Meso- and Microscaled Parts	176
	5.4.1.1 Microcylindrical Compression Test	178
	5.4.1.2 Microforming Experiments	179
	5.4.2 Defect Analysis and Size Effect on Flow-Induced Defects	186
	5.4.2.1 Geometry Size Effect on Folding Defect	187
	5.4.2.2 Effect of Grain Size and Microstructure on Folding Defect	188
	5.5 Summary	191
	References	192
	6 Ductile Fracture and Stress-Induced Defects in Multiscaled Plastic Deformation	193
	6.1 Introduction	193
	6.2 Ductile Fracture and Stress-Induced Defects	194
	6.3 Size Effect on Ductile Fracture	198
	6.3.1 Modeling of Deformation Behaviors Considering Size Effect	199
	6.3.2 Surface Layer Model	200
	6.3.3 Calculation and Comparison of Flow Stress Models in Simple Upsetting	202
	6.3.4 Experiments and Simulations	206
	6.3.5 Size Effect on Ductile Fracture	210
	6.4 Hybrid Constitutive Modeling of Fracture in Microscaled Plastic Deformation	218
	6.4.1 Hybrid Flow Stress Modeling	219
	6.4.1.1 Macroscaled Flow Stress Modeling	219
	6.4.1.2 Hybrid Constitutive Model	221
	6.4.2 Methodology and Calculation	222
	6.4.2.1 Coefficient Calibration Procedure of the Hybrid Constitutive Model	224
	6.4.2.2 Calculation of Microscaled Deformation	226
	6.4.3 Ductile Fracture Prediction	230
	6.4.4 Stress-Induced Fracture Map	231
	6.5 Applicability of DFCs in Microscaled Plastic Deformation	236
	6.5.1 The Uncoupled DFCs	236
	6.5.2 Applicability of the DFCs in Microscaled Plastic Deformation	239
	6.5.2.1 Comparison of the Predicted Fracture Strain	240
	6.5.2.2 Stress-Induced Fracture Map Using Different Fracture Criteria	243
	6.5.2.3 The Generalized Fracture Model Formulation	245
	6.6 Summary	256
	References	257