scholarly journals Introduction to tailored forming

2021 ◽  
Author(s):  
B.-A. Behrens ◽  
J. Uhe
Keyword(s):  
Collaborative Research ◽  
Lightweight Design ◽  
Production Quality ◽  
Research Centre ◽  
Lightweight Construction ◽  
Forming Process ◽  
Process Chains ◽  
Finishing Processes ◽  
Tailored Forming ◽  
Joining Process

AbstractIn recent years, the requirements for technical components have been increasing steadily. This development is intensified by the desire for products with lower weight, smaller size and extended functionality, but at the same time higher resistance against specific loads. Mono-material components manufactured according to established processes reach their limits regarding conflicting requirements. It is, for example, hardly possible to combine excellent mechanical properties with lightweight construction using mono-materials. Thus, a significant increase in production quality, lightweight design, functionality and efficiency can only be reached by combining different materials in one component. The superior aim of the Collaborative Research Centre (CRC) 1153 is to develop novel process chains for the production of hybrid solid components. In contrast to existing process chains in bulk metal forming, in which the joining process takes place during forming or at the end of the process chain, the CRC 1153 uses tailored semi-finished workpieces which are joined before the forming process. This results in a geometric and thermomechanical influence on the joining zone during the forming process which cannot be created by conventional joining techniques. The present work gives an overview of the CRC and the Tailored Forming approach including the applied joining, forming and finishing processes as well as a short summary of the accompanying design and evaluation methods.

scholarly journals Simulation Assisted Process Development for Tailored Forming

2019 ◽  
Vol 949 ◽  
pp. 101-111 ◽  
Author(s):  
Bernd Arno Behrens ◽  
Martin Bonhage ◽  
Dieter Bohr ◽  
Deniz Duran
Keyword(s):  
Collaborative Research ◽  
Elevated Temperatures ◽  
Process Development ◽  
Research Centre ◽  
Process Chains ◽  
Technological Developments ◽  
Deformation Processes ◽  
Production Technologies ◽  
Fuel Costs ◽  
Tailored Forming

Transport industry faces challenges steadily due to rising fuel costs and stricter regulations for the emission of air pollutants. Technological developments that reduce fuel consumption are necessary for sustainable and resource-efficient transport. Innovative production technologies utilising multi-material designs come to the fore in an attempt to fabricate lightweight products with extended functionality. Departing from this motivation, novel process chain concepts for the manufacturing of bi-material forged products are being researched at the Leibniz Universität Hannover in the context of the Collaborative Research Centre (CRC) 1153. The developed technology is referred as Tailored Forming and deals with the deformation and subsequent processing of joined hybrid workpieces to produce application-oriented products. Deformation processes are carried out at elevated temperatures for thermomechanical treatment of the joining zone properties. Researchers make use of numerical simulation in each step in the process chains. This paper explains the challenges associated with induction heating and impact extrusion of bi-material forging billets and presents our solution approaches with the aid of numerical modelling. Experimental validation results and analysis of deformed workpieces are also shown.

scholarly journals Manufacturing and Evaluation of Multi-Material Axial-Bearing Washers by Tailored Forming

Metals ◽  
2019 ◽  
Vol 9 (2) ◽  
pp. 232 ◽  
Author(s):  
Bernd-Arno Behrens ◽  
Alexander Chugreev ◽  
Tim Matthias ◽  
Gerhard Poll ◽  
Florian Pape ◽  
...  
Keyword(s):  
Layer Structure ◽  
Roller Bearing ◽  
Welding Process ◽  
Rolling Contact ◽  
Acoustic Microscopy ◽  
Research Centre ◽  
Forming Process ◽  
Rolling Bearings ◽  
Cylindrical Roller ◽  
Tailored Forming

Components subject to rolling contact fatigue, such as gears and rolling bearings, are among the fundamental machine elements in mechanical and vehicle engineering. Rolling bearings are generally not designed to be fatigue-resistant, as the necessary oversizing is not technically and economically marketable. In order to improve the load-bearing capacity, resource efficiency and application possibilities of rolling bearings and other possible multi-material solid components, a new process chain was developed at Leibniz University Hannover as a part of the Collaborative Research Centre 1153 “Tailored Forming”. Semi-finished products, already joined before the forming process, are used here to allow a further optimisation of joint quality by forming and finishing. In this paper, a plasma-powder-deposition welding process is presented, which enables precise material deposition and control of the welding depth. For this study, bearing washers (serving as rolling bearing raceways) of a cylindrical roller thrust bearing, similar to type 81212 with a multi-layer structure, were manufactured. A previously non-weldable high-performance material, steel AISI 5140, was used as the cladding layer. Depending on the degree of forming, grain-refinement within the welded material was achieved by thermo-mechanical treatment of the joining zone during the forming process. This grain-refinements lead to an improvement of the mechanical properties and thus, to a higher lifetime for washers of an axial cylindrical roller bearing, which were examined as an exemplary component on a fatigue test bench. To evaluate the bearing washers, the results of the bearing tests were compared with industrial bearings and deposition welded axial-bearing washers without subsequent forming. In addition, the bearing washers were analysed micro-tribologically and by scanning acoustic microscopy both after welding and after the forming process. Nano-scratch tests were carried out on the bearing washers to analyse the layer properties. Together with the results of additional microscopic images of the surface and cross-sections, the causes of failure due to fatigue and wear were identified.

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.

Microstructuring by a Combination of Micro Impact Extrusion and Shear Displacement Forming

2013 ◽  
Vol 554-557 ◽  
pp. 893-899 ◽  
Author(s):  
Andreas Schubert ◽  
Stephan F. Jahn ◽  
Benedikt Müller
Keyword(s):  
Cross Sections ◽  
Material Flow ◽  
Extrusion Process ◽  
Shear Displacement ◽  
Raw Material ◽  
Hybrid Process ◽  
Research Centre ◽  
Forming Process ◽  
Process Chains ◽  
Production Technologies

The Collaborative Research Centre SFB/TR 39 PT-PIESA is developing mass production technologies and process chains for the fabrication of aluminium piezo composites, which can be used as raw material for "smart sheet metal" [1]. Microstructuring by forming is a challenging task concerning material flow, tool and process design [2]. In this study, a hybrid forming process combined of micro impact extrusion and shear displacement is presented and discussed. The formed microstructure, depicted in figure 1, consists of ten parallel primary cavities with cross sections of 0.3×0.3 mm² and four larger secondary cavities which are surrounding the primary cavities. High demands are made concerning precision and reproducibility of the cavities' geometry according to the function of the cavities, which is to serve as collets for sensitive piezo rods. The microstructure has to be formed with one stroke of the stamp. Micro backward impact extrusion is chosen for structuring the primary cavities since it allows accurate forming without aligning die plate and stamp due to a flat die plate. Shear displacement forming, which is the selected process for the secondary cavities, requires a structured and aligned die plate but the forming forces are significantly lower than forming the same geometry with an extrusion process which in turn increases the accuracy. The investigations are focused on the characterization of samples formed with the hybrid process in comparison to structures which are formed solely by impact extrusion. Geometric parameters, material flow and process parameters were evaluated to assess the hybrid process. First experiments show promising results, whereas higher degrees of deformation could be reached at lower forming forces. Exemplary, sections for both processes are depicted in figure 2.

Efficient Manufacturing Methods for Hybrid Metal-Polymer Components

2016 ◽  
Author(s):  
Dirk Landgrebe ◽  
Roland Müller ◽  
Rico Haase ◽  
Peter Scholz ◽  
Matthias Riemer ◽  
...  
Keyword(s):  
Injection Molding ◽  
Lightweight Design ◽  
Hybrid Process ◽  
Forming Process ◽  
Cold Forming ◽  
Future Production ◽  
Process Chains ◽  
The Right ◽  
Efficient Manufacturing ◽  
Metal Polymer

Lightweight design for automotive applications gains more and more importance for future products, independent from the powertrain concept. One of the key issues in lightweight design is to utilize the right material for the right application using the right value at the right place. This results irrevocably in a multi-material design. In order to increase the efficiency in manufacturing car components, the number of single parts in a component is decreased by increasing the complexity. Examples for the state of the art are tailored welded blanks in cold forming, tailored tempering in press hardening or metallic inlays in injection molding of polymers. The challenge for future production scenarios of multi-material components is to combine existing technologies for metal- and polymer-based applications in efficient hybrid process chains. This paper shows initial approaches of hybrid process chains for efficient manufacturing of hybrid metal-polymer components. These concepts are feasible for flat as well as for tubular applications. Beside the creation of the final geometric properties of the component by a forming process, integrated joining operations are increasingly required for the efficiency of the production process and the performance characteristics of the final component. Main target of this production philosophy is to create 100% ready-to-install components. This is shown in three examples for hybrid process combinations. The first example deals with the combination of metal forming and injection molding of polymers. Example number two is the application of hybrid metal-polymer blanks. Finally, example number three shows the advantages of process integrated forming and joining of single basic components.

Fortpflanzung von Unsicherheit in Prozessketten*/Propagation of uncertainty in process chains consisting of forming and machining operations

2018 ◽  
Vol 108 (01-02) ◽  
pp. 84-90
Author(s):  
C. Bölling ◽  
F. Hoppe ◽  
F. Geßner ◽  
M. Knoll ◽  
E. Prof. Abele ◽  
...  
Keyword(s):  
Value Chain ◽  
Process Simulation ◽  
Research Centre ◽  
Machining Processes ◽  
Forming Process ◽  
Propagation Of Uncertainty ◽  
Process Chains ◽  
Orbital Forming ◽  
Industrial Value Chain ◽  
Formed Part

Aufeinanderfolgende Umform- und Zerspanungsprozesse stellen im industriellen Umfeld eine typische Wertschöpfungskette dar. Die Auswirkungen von Unsicherheit werden in solchen Prozessketten bislang nur in Einzelprozessen untersucht. Gegenstand der Untersuchungen im Sonderforschungsbereich 805 ist die Entwicklung einer verketteten, geregelten Prozesskette über die unterschiedlichen Bearbeitungsoperationen hinweg. In einem ersten Schritt wird im Rahmen dieses Aufsatzes die Verkettung eines Taumelprozesses mit einer nachfolgenden Reiboperation in einer Simulation untersucht. Die Geometrie der umgeformten Bauteile wird dazu mittels einer entwickelten Schnittstelle in ein passendes Format umgewandelt. Bei der Simulation der Reibbearbeitung wird der Einfluss der Schneidengeometrie sowie unterschiedlicher Bearbeitungsstrategien auf die Auslenkung des Werkzeuges untersucht.   Successive forming and machining processes represent a common industrial value chain. By now, the effect of uncertainty on these process chains has solely been examined with regard to single processes. The research subject of the Collaborative Research Centre 805 is the development of an interlinked closed-loop controlled process chain consisting of various processing operations. This paper presents the investigation results of an orbital forming process simulation succeeded by a reaming operation. An interface has been designed that converts the geometry of the formed part into a suitable format for the subsequent reaming process simulation. By means of the coupled simulation the influence of cutting edge geometry and machining strategies on tool deflection is examined.

scholarly journals Process chain for the manufacture of hybrid bearing bushings

2021 ◽  
Vol 15 (2) ◽  
pp. 137-150
Author(s):  
Susanne Elisabeth Thürer ◽  
Anna Chugreeva ◽  
Norman Heimes ◽  
Johanna Uhe ◽  
Bernd-Arno Behrens ◽  
...  
Keyword(s):  
Extrusion Process ◽  
Steel Tube ◽  
Case Hardening ◽  
Process Chain ◽  
Forming Process ◽  
Die Forging ◽  
Material Contact ◽  
Hybrid Bearing ◽  
Case Hardening Steel ◽  
Tailored Forming

AbstractThe current study presents a novel Tailored Forming process chain developed for the production of hybrid bearing bushings. In a first step, semi-finished products in the form of locally reinforced hollow profiles were produced using a new co-extrusion process. For this purpose, a modular tool concept was developed in which a steel tube made of a case-hardening steel, either C15 (AISI 1015) or 20MnCr5 (AISI 5120), is fed laterally into the tool. Inside the welding chamber, the steel tube is joined with the extruded aluminum alloy EN AW-6082. In the second step, sections from the compound profiles were formed into hybrid bearing bushings by die forging. In order to set the required forming temperatures for each material—aluminum and steel—simultaneously, a tailored heating strategy was developed, which enabled successful die forging of the hybrid workpiece to the desired bearing bushing geometry. Using either of the case-hardening steels in combination with aluminum, this novel process chain made it possible to produce intact hybrid bearing bushings, which showed both macroscopically and microscopically intimate material contact inside the compound zone.

Das intelligente Instandhaltungssystem/The intelligent maintenance system - An approach for the self-learning structuring of maintenance libraries

2017 ◽  
Vol 107 (07-08) ◽  
pp. 530-535
Author(s):  
T. Miebach ◽  
M. Schmidt ◽  
P. Prof. Nyhuis
Keyword(s):  
Collaborative Research ◽  
The Self ◽  
Research Centre ◽  
Maintenance System ◽  
Intelligent Maintenance ◽  
Product Engineering ◽  
The Right ◽  
Self Learning ◽  
Intelligent Maintenance System

Der Fachbeitrag stellt eine Methode vor, mit der sich Bibliotheken von Instandhaltungsmaßnahmen selbstlernend gestalten lassen. Die „Intelligenz“ solcher Systeme bietet mehrfachen Nutzen, einerseits durch die Auswahl der passenden Instandhaltungsmethode zum richtigen Zeitpunkt, andererseits durch die damit verbundene Erhöhung des kompletten Abnutzungsvorrates. Die Ergebnisse sind im Sonderforschungsbereich 653 „Gentelligente Bauteile im Lebenszyklus – Nutzung vererbbarer, bauteilinhärenter Informationen in der Produktionstechnik“ entstanden.   This article describes a method to design a self-learning maintenance library. The benefit derived from the intelligence of those systems refers to the right choice of maintenance measures at the right time and the enhancement of the whole wear margin. The results are part of the Collaborative Research Centre 653: Gentelligent components in their lifecycle – Utilization of inheritable component information in product engineering.

scholarly journals Resilience in Mechanical Engineering - A Concept for Controlling Uncertainty during Design, Production and Usage Phase of Load-Carrying Structures

2018 ◽  
Vol 885 ◽  
pp. 187-198 ◽  
Author(s):  
Lena C. Altherr ◽  
Nicolas Brötz ◽  
Ingo Dietrich ◽  
Tristan Gally ◽  
Felix Geßner ◽  
...  
Keyword(s):  
Collaborative Research ◽  
Mechanical Engineering ◽  
Research Centre ◽  
Product Life ◽  
Usage Phase ◽  
Load Carrying ◽  
Design Production ◽  
Technical Systems

Resilience as a concept has found its way into different disciplines to describe the ability of an individual or system to withstand and adapt to changes in its environment. In this paper, we provide an overview of the concept in different communities and extend it to the area of mechanical engineering. Furthermore, we present metrics to measure resilience in technical systems and illustrate them by applying them to load-carrying structures. By giving application examples from the Collaborative Research Centre (CRC) 805, we show how the concept of resilience can be used to control uncertainty during different stages of product life.

Process-Integrated Projection Welding during Deep Drawing

2016 ◽  
Vol 1140 ◽  
pp. 59-66 ◽  
Author(s):  
Masood Jalanesh ◽  
Andre Miller ◽  
Marco Hehmann ◽  
André Spiekermeier ◽  
Sven Hübner ◽  
...  
Keyword(s):  
Deep Drawing ◽  
Active Surface ◽  
Single Step ◽  
Downstream Process ◽  
Process Step ◽  
Projection Welding ◽  
Process Chains ◽  
Innovative Tool ◽  
Edge Based ◽  
Joining Process

Within deep drawing processes, welding represents an innovative approach to optimising the branched process chains which entail uneconomic process steps in production and transport lines. Previous applications of thermal joining processes in presses required a downstream process step for joining standardised functional elements such as nuts. Within the scope of this publication, a weldable tool system is presented which offers the possibility of welding a deep drawing component to an automatically added non-standardised holder in a single-step deep drawing process without additional dwell time in the bottom dead point. In order to realise this innovative tool system, the interdependencies of deep drawing and projection welding are considered to enable a splash-free welding on flat and curved component areas, such as the rounding of a punch edge. Based on experimental research a special concept for the tool kinematics of welding electronics is drawn up which is based on press kinematics. In addition, this article also deals with electric insulation and the forming forces which have an impact on the welding electrodes integrated into the active surface of the forming tool. Thus, the joining process becomes independent from the type of press.

Sign in / Sign up

Export Citation Format

Share Document