Bulk Metal Forming Processes: Analytical and Numerical Analysis

Metal formingForming is amongNumerical analysis the most widespread manufacturing technologies used for producing semi-finished and near-net-shape metallic components of added value from an initially simple-shaped workpiece. Currently classified in several categories, this technology works by subjecting workpieces to large plastic deformation, causing an irreversible and appreciable change in shape and/or cross-section through rigid tools imparted by industrial machines. This technology was initially limited to standard applications but rose in complexity due to increasingly stringent demands from society namely during the Industrial Revolution which propelled a significant growth in new types of metalworking processes, materials, and equipment. Additionally, the development of analytical, empirical, and numerical modelling of metalworking was identically crucial to allow an efficient designDesign of operations with less reliability on experimentation. Hence, methods of analysis in metal formingForming are among the cornerstone of modern engineering programs in several courses aimed at conveying students with the necessary skills for approaching industrial tasks resourcefully from both economic and ecological points of view. Under these circumstances, this chapter presents a teaching and learning methodology based on exposing undergraduate and graduate students to the fundamentals of metal formingForming through combined analytical and numerical analysisNumerical analysis. The methodology is established according to Project-Based Learning (PBL)PBL interdisciplinary activities with tasks to be carried out in the classroom and away from it as autonomous work. Emphasis is placed on bulk-formingForming processes solved using analytical methods, ideal work, and elementary slab analysis, and numerical methods using finite elements. The authors intend this chapter to provide useful and reproducible insights to junior and senior instructors from manufacturing engineering courses with a clear focus on the technology of metal formingForming.