Trockenrundkneten*/Dry rotary swaging

2015 ◽  
Vol 105 (11-12) ◽  
pp. 830-835
Author(s):  
F. Böhmermann ◽  
H. Hasselbruch ◽  
M. Herrmann ◽  
O. Riemer ◽  
A. Mehner ◽  
...  
Keyword(s):  
Tool Wear ◽  
Metal Forming ◽  
Work Piece ◽  
Light Weight ◽  
Forming Process ◽  
Bulk Metal ◽  
Structured Surfaces ◽  
Bulk Metal Forming ◽  
Rotary Swaging ◽  
Metal Forming Process

Rundkneten ist ein Massivumformverfahren zur Herstellung von Leichtbaukomponenten aus zylindrischen Halbzeugen. Es setzt derzeit einen intensiven Einsatz von Schmiermitteln voraus, um Werkzeugverschleiß zu minimieren und die gewünschte Bauteilqualität bereitzustellen. In dieser Arbeit werden strukturierte und hartstoffbeschichtete Rundknetwerkzeuge vorgestellt. Strukturierung und Beschichtung ersetzen die Funktionen des Schmierstoffes und bilden die Grundlage für eine trockene Prozessführung.   Rotary swaging is an incremental bulk metal forming process for the manufacture of cylindrical light weight components. Nowadays, rotary swaging is carried out under the extensive use of lubricant to avoid abrasive and adhesive tool wear and to provide the desired work piece quality. This work presents rotary swaging tools exhibiting hard coated and structured surfaces substituting the function of the lubricant and allowing for a successful dry rotary swaging.

Holistic Measurement in the Sheet-Bulk Metal Forming Process with Fringe Projection

2012 ◽  
Vol 504-506 ◽  
pp. 1005-1010 ◽  
Author(s):  
Christoph Ohrt ◽  
Wito Hartmann ◽  
Johannes Weickmann ◽  
Markus Kästner ◽  
Albert Weckenmann ◽  
...  
Keyword(s):  
Metal Forming ◽  
Optical Measurement ◽  
Fringe Projection ◽  
Small Scale ◽  
Work Piece ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Deviation Analysis ◽  
Metal Forming Process

Sheet bulk metal forming is a new forming technology, currently developed by several companies and research institutes. It creates high demands on the inspection of parts and tools, especially in the field of in-situ abrasion detection of the forming tool and its impacts on the work piece. This manuscript introduces two optical testing methods for fulfilling these inspection tasks: On the one hand the endoscopic fringe projection as a flexible small scale optical measurement principal with high depth of focus and accuracy for the acquisition of filigree form elements for a continuous abrasion determination and one the other hand the multi-scaled fringe projection for a holistic one shot measurement of the work piece for an adapted, multiscale deviation analysis. The development and advantages of both systems for the sheet bulk metal forming process are shown as well as potentials of the combination of the both systems close to the proposed application next to the production line.

Numerical and Experimental Investigations of Multistage Sheet-Bulk Metal Forming Process with Compound Press Tools

2015 ◽  
Vol 651-653 ◽  
pp. 1153-1158 ◽  
Author(s):  
Bernd Arno Behrens ◽  
Anas Bouguecha ◽  
Milan Vucetic ◽  
Sven Hübner ◽  
Daniel Rosenbusch ◽  
...  
Keyword(s):  
Metal Forming ◽  
Solid Metal ◽  
Experimental Investigations ◽  
Metal Component ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Process Sequence ◽  
Metal Forming Process ◽  
Flange Forming

Sheet-bulk metal forming is a manufacturing technology, which allows to produce a solid metal component out of a flat sheet. This paper focuses on numerical and experimental investigations of a new multistage forming process with compound press tools. The complete process sequence for the production of this solid metal component consists of three forming stages, which include a total of six production techniques. The first forming stage includes deep drawing, simultaneous cutting and following wall upsetting. In the second forming stage, flange forming combined with cup bottom ironing takes place. In the last stage of the process sequence, the component is sized. To investigate and to improve process parameters such as plastic strain distribution, resulting dimensions and process forces, FEA is performed. Based on these results the developed process is designed.

Material Characterization for Sheet-Bulk Metal Forming

2012 ◽  
Vol 504-506 ◽  
pp. 1029-1034 ◽  
Author(s):  
Bernd Arno Behrens ◽  
Kathrin Voges-Schwieger ◽  
Anas Bouguecha ◽  
Jens Mielke ◽  
Milan Vucetic
Keyword(s):  
Metal Forming ◽  
Material Characterization ◽  
Cyclic Load ◽  
Material Behavior ◽  
Forming Force ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Metal Forming Process

Sheet-bulk metal forming is a novel manufacturing technology, which unites the advantages and design solutions of sheet metal and bulk metal forming. To challenge the high forming force the process is superimposed with an oscillation in the main flow of the process. The paper focuses on the characterization of the material behavior under cyclic load and the effects for the sheet bulk metal forming process.

Surface roughness evolution in FEA simulations of bulk metal forming process

Wear ◽  
2012 ◽  
Vol 288 ◽  
pp. 78-87 ◽  
Author(s):  
J. Stahlmann ◽  
E.R. Nicodemus ◽  
S.C. Sharma ◽  
P. Groche
Keyword(s):  
Surface Roughness ◽  
Metal Forming ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Metal Forming Process ◽  
Surface Roughness Evolution

scholarly journals Metrological solutions for an adapted inspection of parts and tools of a sheet-bulk metal forming process

2015 ◽  
Vol 10 (1) ◽  
pp. 51-61 ◽  
Author(s):  
Steffen Matthias ◽  
Andreas Loderer ◽  
Sergej Koch ◽  
Michael Gröne ◽  
Markus Kästner ◽  
...  
Keyword(s):  
Metal Forming ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Metal Forming Process

Influence of Superimposing of Oscillation on Sheet-Bulk Metal Forming

2013 ◽  
Vol 554-557 ◽  
pp. 1484-1489 ◽  
Author(s):  
Bernd Arno Behrens ◽  
Sven Hübner ◽  
Milan Vucetic
Keyword(s):  
Metal Forming ◽  
Dimensional Change ◽  
Extrusion Process ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Bulk Forming ◽  
State Of Stress ◽  
Metal Forming Process ◽  
Excitation Frequencies

Due to novel processes like sheet-bulk metal forming, the requirements for sheet metal forming are increased. Sheet-bulk metal forming is a new interconnected process in which the part itself is manufactured by deep drawing and the gearing will be produced with bulk forming in a combined process at room temperature. This process is characterized by a triaxial state of stress and a triaxial dimensional change with true strains up to  = 1-2 by using sheet blanks. Within the use of superimposing of oscillation on a sheet-bulk metal forming process the required forming force can be reduced and the accuracy of dimension of the part can be improved. Within this paper the influence of the superimposing of oscillation on the sheet bulk metal forming will be shown on combined ironing and external extrusion process. For the superimposing of oscillation different excitation frequencies will be analysed. Furthermore the die clearance will be varied to increase the requirements on the process. Finally the influence of the different excitation frequencies and the different die clearances will be summarized in cause and effect relationship diagram.

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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