Orbital forming of tailored blanks from sheet metal

CIRP Annals ◽  
2012 ◽  
Vol 61 (1) ◽  
pp. 263-266 ◽  
Author(s):  
Marion Merklein ◽  
Raoul Plettke ◽  
Simon Opel
Keyword(s):  
Sheet Metal ◽  
Tailored Blanks ◽  
Orbital Forming

Research on Cold Orbital Forming of Complex Sheet Metal of Aluminum Alloy

2017 ◽  
Vol 139 (6) ◽  
Author(s):  
Xinghui Han ◽  
Qiu Jin ◽  
Lin Hua
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Mobile Phone ◽  
Sheet Metal ◽  
Experimental Results ◽  
Complex Motion ◽  
Flow Lines ◽  
Inner Surface ◽  
Orbital Forming

This study aims at exploring the potentialities of cold orbital forming in forming complex sheet metal. Aiming at a complex mobile phone shell component of aluminum alloy, two technical schemes for cold orbital forming are first presented. Then, the optimized one, i.e., the more complex inner surface of mobile phone shell is arranged to be formed by the rocking punch with a complex motion, is determined by analyzing the nonuniform plastic deformation laws and punch filling behaviors. On the basis of the optimized technical scheme, the blank geometry in cold orbital forming of mobile phone shell is also optimized based on the forming status of the most difficult forming zone. The consistent finite element (FE) simulated and experimental results indicate that under the optimized technical scheme, not only the bosses in the mobile phone shell are fully formed but also the obtained flow lines are reasonable, which proves that the technical scheme presented in this study is feasible and cold orbital forming exhibits huge potentialities in forming complex sheet metal.

New Process Strategies to Manufacture Tailored Blanks out of DP600 by Orbital Forming

2015 ◽  
Vol 794 ◽  
pp. 144-151 ◽  
Author(s):  
Philipp Hildenbrand ◽  
Robert Schulte ◽  
Marion Merklein
Keyword(s):  
Deep Drawing ◽  
Lightweight Design ◽  
High Strength ◽  
Material Efficiency ◽  
Bulk Forming ◽  
Local Material ◽  
Tailored Blanks ◽  
Orbital Forming ◽  
Thickness Variations ◽  
Functional Components

The application of bulk forming operations on sheet metal enables the manufacture of functional components with local wall thickness variations. Using process adapted semi-finished parts with a local material pre-distribution and strain hardening in these processes leads to an increased forming of the functional components. In addition material efficiency is improved. Transferring the positive results acquired with mild deep-drawing steel to high-strength steel tailored blanks enables new possibilities for lightweight design. Given challenges in the manufacture of tailored blanks out of DP600 that reach the same geometry as the ones made of mild deep-drawing steel will be presented in this paper. Furthermore possible ways to overcome them by means of adjusted orbital forming will be presented.

Bending of Tailored Blanks Using Elastic Tools

2014 ◽  
Vol 1018 ◽  
pp. 301-308 ◽  
Author(s):  
Andres Weinrich ◽  
Christoph Becker ◽  
Frauke Maevus ◽  
Sami Chatti ◽  
A. Erman Tekkaya
Keyword(s):  
Sheet Metal ◽  
Local Application ◽  
Lightweight Structures ◽  
Air Bending ◽  
Innovative Process ◽  
Main Challenge ◽  
Tailored Blanks ◽  
Bending Process ◽  
Stress Superposition

Tailored blanks are suitable for the manufacture of lightweight structures due to the load-optimised design. However, the forming of tailored blanks is problematic because of the varying properties. Especially springback is a main challenge to focus on. An innovative process will be discussed which concentrates on the air bending process of sheet metal extended by a local application of a stress superposition to reduce springback.

Investigations on Orbital Forming of Sheet Metals to Manufacture Tailored Blanks with a Defined Sheet Thickness Variation

2013 ◽  
Vol 769 ◽  
pp. 157-164 ◽  
Author(s):  
Raoul Plettke ◽  
Simon Opel
Keyword(s):  
Design Of Experiments ◽  
Sheet Thickness ◽  
Thickness Variation ◽  
Surface Model ◽  
Forming Process ◽  
Cold Forming ◽  
Mould Filling ◽  
Tailored Blanks ◽  
Orbital Forming ◽  
Cutting Processes

Orbital forming is an incremental bulk cold forming process with many advantages. It can produce net-shape or near-net-shape parts that have superior mechanical properties due to work hardening compared to manufacturing with cutting processes or hot forming. In this work the orbital forming process is employed in a closed-die configuration. A rising of the material thickness in the outer areas of a circular sheetmetal blank is enabled by preventing the lateral material flow. The main effects and subsequently the effects of the interaction of parameters were investigated by a two-step design of experiments. A screening plan was used to identify the statistically relevant parameters. The effects were then studied in a subsequent central-composite design of experiments. With the measured data a nonlinear response-surface model was parameterized to describe the dependency of the mould filling on the investigated process parameters. This model was validated experimentally and showed a good agreement to reality. Additionally a new concept for the tool system was developed and investigated. The form-defining cavity can be changed from the upper punch to the counterpunch.

Bending Testing Rig Development through CAE Tools Application

2012 ◽  
Vol 504-506 ◽  
pp. 803-808 ◽  
Author(s):  
Antonio del Prete ◽  
Gabriele Papadia ◽  
Teresa Primo
Keyword(s):  
Sheet Metal ◽  
Process Time ◽  
The Past ◽  
Tailored Blanks ◽  
Bending Process ◽  
Testing Data ◽  
Strategic Role ◽  
Sheet Metal Bending ◽  
Set Up ◽  
Bending Length

Bending can be considered one of easier sheet metal forming processes. In fact, it represents one of the basic variants of applied deformations to metal blanks. However, the numerous research contributions dedicated to sheet metal bending that have been published over the past decade and the constant stream of announcements by R&D departments of machine constructors are strong indications that not all research challenges related to sheet metal bending have been done. This paper reports the developed activity carried out to design a bending testing rig characterized by: a working horizontal axis, a maximum bending length equal to 200 mm, a maximum applicable force equal to 80 kN. A partitioned blankholder has also been designed to allow bending operations on tailored blanks. Moreover, a Graphical User Interface hollows to set up the process parameters and the acquisition of testing data (Temperature and/or Force as function of the process time or punch stroke). CAE tools application had a strategic role to develop the best layout and to find the optimum solutions for the process variables tuning. CAE techniques have allowed to investigate and verify different layout solutions both for the bending process and the structural components of the tooling.

Manufacturing of Sheet Metal Components with Variants Using Process Adapted Semi-Finished Products

2012 ◽  
Vol 504-506 ◽  
pp. 1023-1028 ◽  
Author(s):  
Marion Merklein ◽  
Raoul Plettke ◽  
Thomas Schneider ◽  
Simon Opel ◽  
Daniel Vipavc
Keyword(s):  
Sheet Metal ◽  
Sheet Thickness ◽  
Forming Process ◽  
Local Loads ◽  
Bulk Forming ◽  
Orbital Forming ◽  
Metal Products ◽  
2D And 3D ◽  
Process Combination ◽  
Specific Control

Manufacturing of functional sheet metal products by forming can be realised with the application of conventional bulk forming operations on sheet metals. The challenges of those sheet bulk metal forming processes are high resulting forming forces and the demand on a specific control of material flow. To meet these challenges well-directed thinning of blanks as well as accumulations of material to form functional elements is employed. Due to local loads, simultaneous 2D and 3D stress and strain states occur. Process adapted semi-finished products, containing a defined sheet thickness characteristic, are formed in the presented work by the technologies upsetting and orbital forming. Orbital forming is an incremental bulk forming operation to decrease the forming zone extension and consequently the required process force. Afterwards a process combination of deep drawing and upsetting in order to manufacture a cup-shaped workpiece with external gearing is presented. The results of this integrated single-stage forming process are discussed and subsequently the potential to enhance the process limits is shown by using process adapted semi-finished products.

Manufacturing of Geared Sheet Metal Components Using Flexible Rolled Tailored Blanks

2013 ◽  
Vol 554-557 ◽  
pp. 1459-1470 ◽  
Author(s):  
Simon Opel ◽  
Thomas Schneider ◽  
Marion Merklein
Keyword(s):  
Sheet Metal ◽  
Thickness Distribution ◽  
Sheet Thickness ◽  
Rolling Process ◽  
Sheet Metals ◽  
Bulk Metal ◽  
Gear Teeth ◽  
Material Efficiency ◽  
Tailored Blanks ◽  
The One

Manufacturing of functional sheet metal products with integrated gear teeth by form-ing can be realised with the application of bulk forming operations on sheet metals. Due to the desired part geometry simultaneous 2D and 3D stress and strain states occur during the forming operations. The main challenges of sheet-bulk metal form-ing are high resulting forming forces and the demand on a specific control of the material flow. In addition, there is a distinctive interaction between blank thickness and resulting part quality. To meet these challenges at high material efficiency, the application of tailored blanks with a defined sheet thickness distribution is a promising way. The process adapted semi-finished used in the presented work are formed by a flexible rolling process. First of all, the forming concept for the realization of geared sheet metal components using flexible rolled tailored blanks is presented. Afterwards, the developed rolling machine to produce rotational symmetric tailored blanks is shown, as well as the fundamental process influences during rolling. Based on that, the development of suitable process strategies to produce tailored blanks with a thickened sheet edge is presented. The further processing of those tailored blanks for the realization of external geared sheet metal components will show the advantages compared to the application of conventional sheet metals of constant sheet thickness. Therefore the concept of a combined deep drawing and ironing process is presented. The results show, that on the one hand the material efficiency is increased in comparison to the usage of conventional sheets of the same maximum thickness. On the other hand, the application of flexible rolled tailored blanks improves the accuracy of shape of the gear teeth. Both approaches prove that the application of flexible rolled is an appropriate procedure to enhance the limits of using conventional sheet metals within sheet-bulk metal forming.

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