Incorporation of material behavior in modeling of metal forming and machining processes: A review

Manufacturing process modeling is gaining importance in view of stiff global competition to produce the goods of specified design in an optimal way. In particular, metal forming and machining (both traditional and non-traditional) have been extensively modeled using numerical techniques. Three basic steps of modeling of manufacturing processes are analytical representation of working principle of the process, modeling of material behavior and method of solution. In this paper, a comprehensive review of various approaches of material behavior modeling has been presented. The material behavior modeling has great influence on the design of process, tools and the final product. This aspect is highlighted in the present review. Metal forming processes, traditional machining processes and non-traditional machining processes are considered for the study. Different material models are compared with respect to their suitability for the design of process, tooling and product. Finally, the paper suggests the directions for further research in this area.

► A review of material behavior modeling of metal forming and machining is presented. ► The necessity of modeling the processes for proper design is highlighted. ► Challenging issues and future areas of research are identified.