High-feed milling of tailored surfaces for sheet-bulk metal forming tools

2014 ◽  
Vol 9 (2) ◽  
pp. 215-223 ◽  
Author(s):  
Rouven Hense ◽  
Christoph Wels ◽  
Petra Kersting ◽  
Ulrich Vierzigmann ◽  
Maria Löffler ◽  
...  
Keyword(s):  
Metal Forming ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Tailored Surfaces ◽  
High Feed ◽  
Forming Tools

scholarly journals Influence of Tailored Surfaces and Superimposed-Oscillation on Sheet-Bulk Metal Forming Operations

2020 ◽  
Vol 4 (2) ◽  
pp. 41
Author(s):  
Bernd-Arno Behrens ◽  
Wolfgang Tillmann ◽  
Dirk Biermann ◽  
Sven Hübner ◽  
Dominic Stangier ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Metal Forming ◽  
High Strength Steels ◽  
High Strength ◽  
Compression Tests ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Tailored Surfaces ◽  
High Feed

Producing complex sheet metal components in fewer process steps motivated the development of the innovative forming process called sheet-bulk metal forming (SBMF). In this process, sheet metal forming and bulk-metal forming are combined to create a unique forming process in which a component with external and internal gearing is produced in three production steps. However, the high degrees of deformation that occur using high-strength steels and the number of different process steps result in high process forces, strongly limiting the service life of tools. To reduce the forming force during SBMF processes, tool and process modifications were investigated. Therefore, plane-strain compression tests were conducted to examine the influence of a CrAlN PVD coating and tailored surfaces produced by high-feed milling (HF) of tool-active elements on the material flow of the specimens. In addition to the tool-sided modifications, the influence of an oscillation overlay during the forming process was investigated. Based on the results of the compression tests, the surfaces of the active tool elements of the SBMF process were modified in order to transfer the basic experimental results to the production of a functional component. The friction is thus adapted locally in the SBMF process.

scholarly journals Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

2020 ◽  
Vol 7 ◽  
pp. 9 ◽  
Author(s):  
Florian Pilz ◽  
Johannes Henneberg ◽  
Marion Merklein
Keyword(s):  
Sheet Metal ◽  
Metal Forming ◽  
Extrusion Process ◽  
Process Conditions ◽  
Functional Elements ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Lateral Extrusion ◽  
Component Design ◽  
Tailored Surfaces

Increasing demands in modern production pose new challenges to established forming processes. One approach to meet these challenges is the combined use of established process classes such as sheet and bulk forming. This innovative process class, also called sheet-bulk metal forming (SBMF), facilitates the forming of minute functional elements such as lock toothing and gear toothing on sheet-metal bodies. High tool loads and a complex material flow that is hard to control are characteristic of SBMF. Due to these challenging process conditions, the forming of functional elements is often insufficient and necessitates rework. This negatively affects economic efficiency. In order to make use of SBMF in industrial contexts, it is necessary to develop measures for improving the forming of functional elements and thereby push existing forming boundaries. This paper describes the design and numerical replication of both a forward and a lateral extrusion process so as to create involute gearing in combination with carrier teeth. In a combined numerical-experimental approach, measures for extending the die filling in sheet-metal extrusion processes are identified and investigated. Here, the focus is on approaches such as process parameters, component design and locally adjusted tribological conditions; so-called ‘tailored surfaces’. Based on the findings, fundamental mechanisms of action are identified, and measures are assessed with regard to their potential for application. The examined approaches show their potential for improving the forming of functional elements and, consequently, the improvement of geometrical accuracies in functional areas of the workpieces.

Machines and Tools for Sheet-Bulk Metal Forming

2011 ◽  
Vol 473 ◽  
pp. 91-98 ◽  
Author(s):  
Marion Merklein ◽  
A. Erman Tekkaya ◽  
Alexander Brosius ◽  
Simon Opel ◽  
Lukas Kwiatkowski ◽  
...  
Keyword(s):  
Metal Forming ◽  
Incremental Forming ◽  
Batch Size ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
New Process ◽  
Novel Approaches ◽  
The Individual ◽  
Forming Tools ◽  
Functional Components

The demand on closely-tolerated and complex functional components in the automotive sector, like e.g. synchronizer rings, leads to the development of a new process-class named “sheet-bulk metal forming”. Within this technology bulk metal forming operations are applied on sheet metals. In the following two novel approaches considering machines and tools for sheet-bulk metal forming are presented. The first approach aims on a technology based on rolling, which is suitable for mass production. The second one is an incremental forming solution for low batch production. Both machine concepts allow the application of different forming strategies to manufacture individual tailored semi-finished products in term of a pre-distribution of material. These products feature variable sheet thicknesses and mechanical properties, which can be adapted to their case of applica-tion. Depending on the individual batch size, the blanks can be finished to functional parts by sub-sequent forming processes like deep drawing and upsetting, extrusion or incremental forming. In this paper the case of an incremental tooth-forming is mainly considered. Forming sequences and resulting loads are modeled and calculated by finite elements simulations for all discussed processes to serve as a basis for the design and dimensioning of the machine components and forming tools.

Experimental and numerical analysis of tribological effective surfaces for forming tools in Sheet-Bulk Metal Forming

2016 ◽  
Vol 10 (1) ◽  
pp. 37-50 ◽  
Author(s):  
Petra Kersting ◽  
Daniel Gröbel ◽  
Marion Merklein ◽  
Peter Sieczkarek ◽  
Sebastian Wernicke ◽  
...  
Keyword(s):  
Numerical Analysis ◽  
Metal Forming ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Forming Tools

Analysis of Effectiveness of Locally Adapted Tribological Conditions for Improving Product Quality in Sheet-Bulk Metal Forming

2015 ◽  
Vol 794 ◽  
pp. 81-88 ◽  
Author(s):  
Maria Löffler ◽  
Daniel Groebel ◽  
Ulf Engel ◽  
Kolja Andreas ◽  
Marion Merklein
Keyword(s):  
Metal Forming ◽  
Material Flow ◽  
Operating Time ◽  
Wear Behaviour ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Geometrical Features ◽  
Tailored Surfaces ◽  
Economic Developments ◽  
Functional Components

Due to current ecological and economic developments there is a growing demand for functional components with complex and closely tolerated geometrical features. Conventional sheet and bulk metal forming operations leads to products which are often limited in their geometrical and functional variety. A promising approach is the process-class sheet-bulk metal forming (SBMF). SBMF is characterised by the application of bulk and sheet forming operations on sheet metals [1]. This combination leads to locally and temporally varying load conditions regarding stress as well as strain states. In order to get high quality parts, controlling the material flow is of major importance. Modified Surfaces, so-called tailored surfaces represent an innovative approach to control the material flow. The objective of the current study is the experimental investigation of the effectiveness of locally adapted tribological conditions using workpiece-and tool-sided tailored surfaces within SBMF processes. The study has shown that the local adaption of workpiece and tool surface increased the heights of functional elements. Thus, using locally adapted tribological conditions leads to an improvement of the quality of the produced gearing components. In a further step the influence of surface modifications on the surface properties of the manufactured components are analysed. Additionally, investigations regarding the wear behaviour of tool-sided surface adaptions lead to the assumption, that the effectiveness of tailored surfaces is reduced during the operating time of the tools.

Influence of Surface Modifications on Friction, Using High-Feed Milling and Wear Resistant PVD-Coating for Sheet-Metal Forming Tools

2015 ◽  
Vol 639 ◽  
pp. 275-282 ◽  
Author(s):  
Dirk Biermann ◽  
Dennis Freiburg ◽  
Rouven Hense ◽  
Wolfgang Tillmann ◽  
Dominic Stangier
Keyword(s):  
Metal Forming ◽  
Material Flow ◽  
Functional Integration ◽  
Work Piece ◽  
Efficient Production ◽  
Bulk Metal ◽  
Wear Resistant ◽  
Structured Surfaces ◽  
Bulk Metal Forming ◽  
High Feed

Increasing technological requirements, as well as the demand for an efficient production demands high performance materials and enhanced manufacturing processes. The development of a new manufacturing process, sheet-bulk metal forming (SBMF), is one approach to produce lightweight forming parts with an increased number of functional properties while, at the same time, combining the advantages of sheet and bulk metal forming. For SBMF processes, the specific adjustment of the friction between tool and workpiece for a specifically designed material flow, which is called tailored friction, is of great importance. The reduction of friction is essential in order to ensure a homogeneous forming zone. However, a higher friction can be used to control the material flow to increase the local thickness of the work piece for additional functional integration. This paper shows the development of surface structures for SBMF tools by means of high-feed milling. Process parameters like the tilt angle or the feed are varied to influence the surface parameters of the structures, which results in different tribological properties of the forming tool. The structured surfaces are subsequently coated with a wear resistant CrAlN coating, processed by a magnetron-sputtering process (PVD) to enhance the lifetime and performance of the forming tool. Finally, a ring compressing test is used to investigate the tribological behavior of the coated structures.

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