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.

scholarly journals A New Strategy for Manufacturing Tailored Blanks by a Flexible Rolling Process

2016 ◽  
Vol 854 ◽  
pp. 99-105 ◽  
Author(s):  
Philipp Hildenbrand ◽  
Michael Lechner ◽  
Marion Merklein
Keyword(s):  
Sheet Thickness ◽  
High Strength Steels ◽  
High Strength ◽  
Rolling Process ◽  
Flexible Rolling ◽  
Material Efficiency ◽  
Tailored Blanks ◽  
First Results ◽  
Process Strategy ◽  
Functional Components

Applying bulk forming processes on sheet metals enables the manufacturing of functional components with local wall thickness distributions. Using tailored blanks improves the forming of the functional components and increases the material efficiency. One process for manufacturing tailored blanks with defined sheet thickness distributions is a flexible rolling process. However, this process requires a complex process strategy. Additionally, tailored blanks out of high-strength steels from this process have failed in subsequent forming. Thus, a new rolling concept with a defined shaping of the material into a die cavity has been developed. This new concept requires the development of a new process strategy. In this paper, the general qualification and first results of the new concept are presented.

Flexible Rolling of Process Adapted Semi-Finished Parts and its Application in a Sheet-Bulk Metal Forming Process

2015 ◽  
Vol 639 ◽  
pp. 259-266 ◽  
Author(s):  
Philipp Hildenbrand ◽  
Thomas Schneider ◽  
Marion Merklein
Keyword(s):  
Sheet Thickness ◽  
Rolling Process ◽  
Forming Process ◽  
Flexible Rolling ◽  
Bulk Forming ◽  
Tailored Blanks ◽  
Metal Forming Process ◽  
Thickness Variations ◽  
Process Strategy ◽  
Functional Components

By applying bulk forming processes on sheet metals, thin-walled functional components with locally restricted wall thickness variations can be manufactured by forming operations. Using tailored blanks with a modified sheet thickness gradient instead of conventional blanks, an efficient controlling of the material flow can be achieved. One possible process to manufacture these semi-finished parts is a flexible rolling process. Based on an established process strategy new results for steels of differing strength and work-hardening behavior are presented in this paper. The influences of each material on the resulting process forces and blank properties regarding the same target geometry are discussed. The tailored blanks are hereby analyzed by their geometrical dimensions, like sheet thickness, and their mechanical properties, e.g. hardness distribution. Additionally, the possibilities of processing these tailored blanks in a deep-drawing and upsetting process are presented with a hereby focus on the residual formability of the tailored blanks.

Sheet-Bulk Metal Forming of Preformed Sheet Metal Parts

2011 ◽  
Vol 473 ◽  
pp. 83-90 ◽  
Author(s):  
Thomas Schneider ◽  
Marion Merklein
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Metal Forming ◽  
Sheet Plane ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Sheet Metal Parts ◽  
Bulk Forming ◽  
Process Factors ◽  
Functional Components

Due to ecological and economic challenges there is a rising demand on closely-tolerated complex functional components. Regarding short process chains and improved mechanical properties conventional forming processes are often limited. A promising approach to meet these requirements can be seen in the combination of traditional sheet and bulk metal forming processes, to form sheet metals out of the sheet plane with typical bulk forming operations. The challenge of applying conventional bulk forming operations on sheet metal is the interaction between regions of high and low deformation, which is largely unknown in literature. To analyze this topic fundamentally, a process combination of deep drawing and upsetting is developed for manufacturing tooth-like elements at pre-drawn cups. To fully understand material flow out of the sheet plane into the tooth cavity and to identify and qualify process factors depending on the functional elements´ geometry and friction, a single upsetting stage forming a simplified model of the blank is virtually analyzed with finite-element simulation. By inhibiting the forming history of the pre-drawn blank, the upsetting process can be investigated without interactions with a previous deep drawing operation.

scholarly journals Deep Drawing of High-Strength Tailored Blanks by Using Tailored Tools

Materials ◽  
2016 ◽  
Vol 9 (2) ◽  
pp. 77 ◽  
Author(s):  
Thomas Mennecart ◽  
Hamad ul Hassan ◽  
Alper Güner ◽  
Noomane Ben Khalifa ◽  
Mohamad Hosseini
Keyword(s):  
Deep Drawing ◽  
High Strength ◽  
Tailored Blanks

Effects of Weld Line in Deep Drawing of Tailor Welded Blanks of High Strength Steels

2014 ◽  
Vol 611-612 ◽  
pp. 955-962 ◽  
Author(s):  
Thomas Mennecart ◽  
Alper Güner ◽  
Nooman Ben Khalifa ◽  
A. Erman Tekkaya
Keyword(s):  
Deep Drawing ◽  
Applied Load ◽  
Lightweight Design ◽  
Weld Line ◽  
Base Material ◽  
High Strength Steels ◽  
High Strength ◽  
Fe Model ◽  
Tailor Welded Blanks ◽  
Base Materials

Due to the increase of lightweight design in car bodies, there is a raise in use of tailored welded blanks (TWB). With these blanks it is possible to strengthen the car body where it is necessary. This can lead to less weight. In the case of tailored welded blanks, there is a weld line, which influences the deep drawing behavior significantly during forming. In the presented results two different high strength steels (HCT980X and HCT600X) are welded together. One forming operation is performed, in which the weld line is positioned differently. The results show the influence of the weld line on the forming behavior which is realized by the comparison of deep drawn monolithic parts with the deep drawn tailored welded blanks. While the monolithic parts could be formed without failure, the forming of tailored welded blanks was accompanied by cracks in dependency to the weld line orientation and the applied load in this region. The results also show that the failure occurs in the base material and that the weld line is not damaged by the applied load. After the characterization of the base materials and the weld material, a numerical modelling of the whole TWB could be realized in this work. Two different ways of modelling techniques of the weld line are compared and the necessity of the consideration of the weld line properties is demonstrated. Furthermore, in consideration of the weld line properties in the FE-Model, it is possible to show that the weld line resists the forming operation without failure.

Characterization of the Bonded Connection in Hybrid-Steel-GFRP-Laminates

2017 ◽  
Vol 742 ◽  
pp. 408-415 ◽  
Author(s):  
Arne Busch ◽  
Robert Brandt
Keyword(s):  
Energy Release Rate ◽  
Glass Fiber ◽  
Energy Release ◽  
Release Rate ◽  
Lightweight Design ◽  
Quantitative Description ◽  
High Strength ◽  
Reinforced Plastics ◽  
Hybrid Laminates ◽  
Functional Components

Intrinsic hybrid laminates are well established since many years in aerospace engineering, e.g. Glass Laminate Aluminium Reinforced Epoxy (GLARE) is widely used as a substitute for aluminium sheets of the outer shell of modern aircrafts. The reduction of density and an increased stiffness by compounding glass fiber and aluminium makes GLARE advantageous. Driven by environmental protection acts and the need for lightweight design material compounds attract more awareness in the automotive engineering as well. Functional components like chassis springs are well predestined for the application of glass fiber reinforced plastics (GFRP). Therefore, an intrinsic hybrid made up by GFRP and a high strength steel has recently been developed and characterized. This investigation sets the focus on the interface between GFRP and steel. Double cantilever beam tests (mode I) and shear tests (mode II) are conducted in order to measure the energy release rate and the shear strength of the considered interface. A variety of surface treatments of steel layer has been characterized by this approach. The results show up that good adhesion can be achieved by silane and titanium dioxide primers, however, the variation within the data is significantly higher than for other surface treatment variants. Furthermore, the increase of the energy release rate by fiber bridging effects is considered as well and an approach for its quantitative description by a power law is presented.

Orbital forming of tailored blanks with two-sided local material thickening

2018 ◽  
Vol 97 (9-12) ◽  
pp. 3469-3478 ◽  
Author(s):  
P. Hildenbrand ◽  
M. Lechner ◽  
M. Vogel ◽  
H. Herrmann ◽  
M. Merklein
Keyword(s):  
Local Material ◽  
Tailored Blanks ◽  
Orbital Forming

Investigations on the Mechanical Properties and Formability of Friction Stir Welded Tailored Blanks

2007 ◽  
Vol 344 ◽  
pp. 143-150 ◽  
Author(s):  
Gianluca Buffa ◽  
Livan Fratini ◽  
Marion Merklein ◽  
Detlev Staud
Keyword(s):  
Mechanical Properties ◽  
Stress Condition ◽  
Research Effort ◽  
High Strength Steels ◽  
High Strength ◽  
Tensile Tests ◽  
Friction Stir ◽  
Tailored Blanks ◽  
Sheet Stamping ◽  
Wide Range

Tight competition characterizing automotive industries in the last decades has determined a strong research effort aimed to improve utilized processes and materials in sheet stamping. As far as the latter are regarded light weight alloys, high strength steels and tailored blanks have been increasingly utilized with the aim to reduce parts weight and fuel consumptions. In the paper the mechanical properties and formability of tailored welded blanks made of a precipitation hardenable aluminum alloy but with different sheet thicknesses, have been investigated: both laser welding and friction stir welding have been developed to obtain the tailored blanks. For both welding operations a wide range of the thickness ratios has been considered. The formability of the obtained blanks has been characterized through tensile tests and cup deep drawing tests, in order to show the formability in dependency of the stress condition; what is more mechanical and metallurgical investigations have been made on the welded joints.

Hot Spline Forming of Ultra-High Strength Steel Gear Drum Using Resistance Heating

2014 ◽  
Vol 622-623 ◽  
pp. 201-206 ◽  
Author(s):  
Kenichiro Mori ◽  
Tomoyoshi Maeno ◽  
Shohei Nakamoto
Keyword(s):  
Deep Drawing ◽  
High Strength Steel ◽  
Side Wall ◽  
High Strength ◽  
Axial Direction ◽  
Resistance Heating ◽  
Sectional Area ◽  
Forming Process ◽  
Cross Sectional ◽  
Ultra High Strength Steel

A hot spline forming process of die-quenched gear drums using resistance heating of a side wall of a cup formed by cold deep drawing and ironing was developed. The side wall having uniform cross-sectional area is resistance-heated by passage of the current in the axial direction, the heated side wall of the drawn cup is ironed and is finally die-quenched. The gear drum was successfully formed and the hardness was between 400 and 500 HV. Not only the formability was improved but also the formed dram was hardly oxidised because of rapid resistance heating.

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