Research of Forming Process of Surface Quality During Machining with Free Abrasive

2021 ◽  
pp. 112-121
Author(s):  
A. A. Kulkov ◽  
A. Y. Popov ◽  
A. Y. Korytov
Keyword(s):  
Surface Quality ◽  
Forming Process ◽  
Free Abrasive

Schwingungsüberlagertes Axialformen/Superimposed Oscillated Axial Forming

2020 ◽  
Vol 110 (11-12) ◽  
pp. 838-843
Author(s):  
Philipp Müller ◽  
Bernd-Arno Behrens ◽  
Sven Hübner ◽  
Hendrik Vogt ◽  
Daniel Rosenbusch ◽  
...  
Keyword(s):  
Surface Quality ◽  
Economic Importance ◽  
Combined Effect ◽  
Wird Eine ◽  
Forming Force ◽  
Forming Process ◽  
Forming Technology ◽  
Great Economic Importance ◽  
Gear Geometry

Techniken zur Steigerung der Formgebungsgrenzen in der Umformtechnik sind von hoher wirtschaftlicher Bedeutung. In dieser Arbeit wird eine Schwingungsüberlagerung im Krafthauptfluss eines Axialformprozesses zur Ausprägung einer Verzahnungsgeometrie untersucht. Die Auswirkungen der Schwingung auf die erzielbare Ausfüllung der Zahnkavitäten werden analysiert sowie die Parameter Schmierung und Oberflächengüte der Halbzeuge in ihrer kombinierten Wirkung untersucht. Es konnte eine Reduzierung der mittleren Umformkraft sowie eine Erhöhung der Formfüllung festgestellt werden. Techniques for extending the production limits in forming technology are of great economic importance. In this research, a superimposed oscillation in the main force flow of an axial forming process to form an axial gear geometry is investigated. The effects of the superimposed oscillation on the achievable form-filling of the tooth cavities are analyzed and the parameters lubrication and surface quality of the semi-finished products are investigated in their combined effect. A reduction of the averaged forming force as well as an increase of the form-filling could be achieved.

Influence of Manufacturing Process on the Fatigue Strength of Gears

2014 ◽  
Vol 1018 ◽  
pp. 269-276
Author(s):  
Andrea Reiß ◽  
Ulf Engel
Keyword(s):  
Fatigue Strength ◽  
Surface Quality ◽  
Fatigue Behavior ◽  
High Surface ◽  
Research Work ◽  
Dimensional Accuracy ◽  
Cold Forging ◽  
Hardness Distribution ◽  
Forming Process ◽  
High Surface Quality

With cold forging processes it is possible to produce parts characterized by high strength, high dimensional accuracy and high surface quality. In order to optimize the forming process and to be able to use the advantages of cold forging specifically and combined, it is necessary to find correlations between manufacturing parameters on the one side, strength and other properties like hardness distribution and surface quality of the component on the other side. The research work covered in this paper focuses on the correlation of the components properties influenced by its manufacturing history and their fatigue strength. The used component is a gear produced by a lateral cold forging process. For the investigations an experimental setup has been designed. The aim for the design of the setup is to reproduce the real contact condition for the contact of two gears. To obtain different component properties the production process of the gear was varied by producing the parts by a milling operation. First of all, the components’ properties, for example hardness distribution, remaining residual stresses, orientation of fibers and surface quality, were determined. The components’ fatigue behavior was determined using a high frequency pulsator and evaluated in terms of finite life fatigue strength and fatigue endurance limit. These examinations were used to produce Woehler curves for the differently manufactured components with a certain statistical data analysis method.

Research on Subsurface Damage of Lapping Sapphire with Diamond Fixed Abrasive

2020 ◽  
Vol 866 ◽  
pp. 143-151
Author(s):  
Jian Bin Wang ◽  
Yong Qiang Tong ◽  
Ben Chi Jiang ◽  
Da Shu ◽  
Gang Wang
Keyword(s):  
Surface Quality ◽  
Surface Damage ◽  
Subsurface Damage ◽  
Indentation Fracture ◽  
Damage Layer ◽  
Damage Depth ◽  
The Difference ◽  
Fixed Abrasive ◽  
Free Abrasive

The depth of surface/subsurface damage layer is the key index of surface quality of sapphire. In this paper, that depth model of the surface/subsurface damage lay characterized by the crack length was established according to the mechanical theory of indentation fracture. The cutting relation between abrasive and workpiece and the difference of the depth of subsurface damage crack are analyzed. It is preliminarily estimated that the length of sub-surface damage crack of free abrasive sapphire is about 2.46 times that of fixed abrasive when considering only the contact hardness of abrasive grain under static load. Diamond abrasives with size of W20 were adopted to carry out experiments in free and fixed lapping methods. The results show that the surface/subsurface damage depth is 9.87μm and 3.63μm respectively. It is easier to obtain good sub-surface quality by using the fixed abrasive method than free abrasive at the same particle size.

scholarly journals Investigations of the Influence of a Superimposed Oscillation on the Fatigue Strength

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1274
Author(s):  
Bernd-Arno Behrens ◽  
Sven Hübner ◽  
Daniel Rosenbusch ◽  
Philipp Müller
Keyword(s):  
Fatigue Strength ◽  
Surface Quality ◽  
Collaborative Research ◽  
Mechanical Vibration ◽  
Research Centre ◽  
Term Strength ◽  
Forming Process ◽  
Vibration Resistance ◽  
Threshold Range

Within the scope of the transregional collaborative research centre TCRC73, the effects of an oscillation superimposed forming process for the production of a demonstrator component are investigated. Previous studies in this field were limited to a consideration of the process-related parameters such as the influence of the plastic work and the friction or the component-related parameters such as the influence of the surface quality and the mold filling. This research concentrates on the consideration of the mechanical vibration resistance of components that were manufactured superimposed oscillated. For this purpose, Wöhler tests are conducted in which the fatigue strength of superimposed oscillation pre-stretched test samples and oscillation-free pre-stretched test samples are investigated. First, Wöhler curves are generated in the tensile threshold range for tensile samples made out of the steels DC04 and DP600. Subsequently, tensile specimens are pre-stretched superimposed oscillated and oscillation-free. These specimens are subjected to a tensile threshold load until they break. The influence of the superimposed oscillation forming on the long-term fatigue of components is derived from the comparison of the bearable load cycles. Investigations of the microstructure of the specimens are conducted in order to draw conclusions about the influence on the long-term strength.

Research on Catalyst Penetration Process of Patternless Casting Manufacturing Technique

2014 ◽  
Vol 609-610 ◽  
pp. 1515-1520 ◽  
Author(s):  
Wei Dong Yang ◽  
Zhan Qun Shi ◽  
Li Li
Keyword(s):  
Rapid Prototyping ◽  
Surface Quality ◽  
Dimensional Accuracy ◽  
Single Droplet ◽  
Forming Process ◽  
Penetration Process ◽  
Forming Quality ◽  
Main Factors ◽  
Sand Particles

Pattenless Casting Manufacturing (PCM) technique is a kind of Rapid Prototyping based on droplet injection, using discrete nozzle to jet the catalyst. The quality of scanning lines has the most important effect on the sand strength, its surface quality and dimensional accuracy. The penetration and curing rules of the catalyst in the resined-sand particles are the main factors to determine the shape of the scanning lines. In order to study the penetration rules of the catalyst in the resined-sand, the penetration process of a single droplet and scanning lines are analyzed theoretically and verified by experiments. The important parameters of the forming process are determined based on the research and experimental results. It will provide the foundation to improve the forming quality of PCM technique.

Investigation on the Influence of Manufacturing Parameters on the Fatigue Strength of Components

2013 ◽  
Vol 554-557 ◽  
pp. 280-286 ◽  
Author(s):  
Andrea Reiss ◽  
Ulf Engel ◽  
Marion Merklein
Keyword(s):  
Fatigue Strength ◽  
Surface Quality ◽  
Fatigue Behavior ◽  
High Surface ◽  
Research Work ◽  
Cold Forging ◽  
Hardness Distribution ◽  
Forming Process ◽  
High Surface Quality ◽  
Manufacturing Parameters

With cold forging processes it is possible to produce parts characterized by high strength, high dimensional accuracy and high surface quality. In order to optimize the forming process and to be able to use the advantages of cold forging specifically and combined, it is necessary to find correlations between the manufacturing parameters, the strength and the properties, like hardness distribution and surface quality, of the component. The research work covered in this paper focuses on the influence of the components properties influenced by its manufacturing history on their fatigue strength. The used component is a flange hub, produced by a four-stage cold forging process. To obtain different component properties the production process of the hub was varied for example by changing the heat treatment or by producing the parts by turning process. First of all, the components’ properties, for example hardness distribution, remaining residual stresses, orientation of fibers and surface quality, were determined. Moreover, a special experimental setup for the fatigue tests has been designed. The components’ fatigue behavior was determined using a high frequency pulsator and evaluated in terms of finite life fatigue strength and fatigue endurance limit. These examinations were used to produce Woehler curves for the differently manufactured components with a certain statistical data analysis method.

Experimental Investigations of Different Tool Concepts for Rotary Peen Forming

2013 ◽  
Vol 549 ◽  
pp. 53-60 ◽  
Author(s):  
Christoph Russig ◽  
Markus Bambach ◽  
Gerhard Hirt
Keyword(s):  
Surface Quality ◽  
Machine Design ◽  
Experimental Investigations ◽  
Plastic Layer ◽  
Circular Trajectory ◽  
Forming Process ◽  
The Third ◽  
Peen Forming ◽  
Structural Parts ◽  
Localized Plastic Deformation

Rotary Peen Forming (RPF) is a new peen forming process, comparable to Shot Peen Forming (SPF), in which the shot is held by a flexible connection and moved on a circular trajectory. Hence, RPF uses less machine components and therefore offers a compact machine design and a more flexible use than SPF. Just as conventional Shot Peen Forming the RPF process causes localized plastic deformation but involves tangential components which can create shear deformation in the plastic layer. In this paper, three different RPF tool concepts are compared and the applicability of Rotary Peen Forming for the production of slightly curved parts is analyzed. The first design offers a stochastic impact distribution, the second design leads to deterministic impacts. The third one is a further enhancement of the previous designs and combines the advantages of both. In contrast to previous tests a new, stiffer testing setup was used which offers good comparability of the tool concepts. Particularly the forming potential in terms of the realization of high curvatures and the surface quality are investigated. Depending on the tool concept the surface quality differs significantly, but generally RPF allows the forming of curvatures that are commonly used for aerospace structural parts.

Investigation of the Influence of a Superimposed Oscillated Forming Process on Forming Characteristics

2021 ◽  
Vol 883 ◽  
pp. 181-186
Author(s):  
Philipp Müller ◽  
Sven Hübner ◽  
Daniel Rosenbusch ◽  
Hendrik Vogt ◽  
Bernd Arno Behrens
Keyword(s):  
Surface Quality ◽  
Sheet Metal ◽  
Material Flow ◽  
New Technologies ◽  
High Surface ◽  
Efficient Production ◽  
Forming Process ◽  
Forming Technology ◽  
Forming Characteristics ◽  
Functional Components

The increasing demand for resource-efficient production methods is driving the development of new technologies. Sheet bulk metal forming (SBMF) offers the possibility to combine sheet metal and bulk forming operations. This allows the production of complex functional components with secondary forming elements from sheet metal. Compared to other production techniques such as machining, a more efficient use of material can be achieved. Further advantages are a near net shape production and increased strain hardening. SBMF processes are limited by forming technology boundaries. These include high forming forces, incomplete mould fillings and limited surface qualities. In this research, the possibility of enhancing the material flow, improving surface quality and reducing the tool loads in SBMF-processes is investigated by using a superimposed oscillation. The focus here is on achieving a high surface quality of components produced by forming technology and an enhanced material flow during forming. For this purpose, a forming process for ironing an axial gear geometry is superimposed with an oscillation in the main force flow.

Effect of Pattern-Less Forming Process on Quality of Sand Mold Surface

2020 ◽  
Vol 1001 ◽  
pp. 115-120
Author(s):  
Li Jun Guo ◽  
Zhong De Shan ◽  
Er Biao Jiang
Keyword(s):  
Surface Quality ◽  
Great Influence ◽  
Sand Mold ◽  
Extrusion Force ◽  
Mold Surface ◽  
Object Surface ◽  
Forming Process ◽  
Abrasive Resistance ◽  
Sand Material

The pattern-less sand mold was used as the research object, surface quality of sand mold was carried out by using surface abrasion tester. In this paper, the influence of sand material such as the types of sand, resin contents and extrusion pressure on the surface quality was studied through the single-factor test. The results showed that: different sand mold had different surface abrasive resistance. The angle coefficient of sand has a great influence on the surface abrasive resistance of the sand mold. With the increase of extrusion force, the surface abrasive resistance of sand mold increased. And as the resin content increased, the surface abrasive resistance of sand mold continued to increase.

Modified DLC-Coated Guide Pads for BTA Deep Hole Drilling Tools

2010 ◽  
Vol 438 ◽  
pp. 195-202 ◽  
Author(s):  
Dirk Biermann ◽  
Nadine Kessler ◽  
Thorsten Upmeier ◽  
Thomas Stucky
Keyword(s):  
Surface Quality ◽  
Borehole Wall ◽  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Forming Process ◽  
Workpiece Material ◽  
Drilling Depth ◽  
Deep Hole Drilling ◽  
Drilling Tools

The BTA (Boring and Trepanning Association) deep hole drilling process is commonly used to machine boreholes with a large drilling depth-to-diameter ratio (l/D) and outstanding workpiece quality. The asymmetric tool design leads to a nonzero radial component of the cutting force and the passive force, which are conducted to the borehole wall by so-called guide pads. These guide pads smooth the borehole wall by a forming process and improve the surface quality. Processes, that machine materials with a high adhesion tendency, such as high alloy stainless steel, suffer from poor surface quality in the borehole and the adhesion from the workpiece material on the guide pads. In this paper modified Diamond-Like-Carbon (DLC) coated guide pads for BTA deep hole drilling tools are investigated. The scope of the experiments was the reduction of the adhesion by reducing the friction coefficient of the guide pads, as well as the improvement of the quality of the borehole wall.

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