Contribution for the Simulation of Tube-Bulk Forming by Lateral Extrusion of Flanges and Collars in Light Weight Components

2014 ◽  
Vol 966-967 ◽  
pp. 569-579
Author(s):  
Marcus Kannewurf ◽  
Mathias Liewald
Keyword(s):  
Metal Forming ◽  
Process Development ◽  
High Strength ◽  
Extrusion Process ◽  
Light Weight ◽  
German Research Foundation ◽  
Industrial Manufacturing ◽  
Lateral Extrusion ◽  
Research Activities ◽  
Main Challenge

Joining using forming processes in the field of bulk metal forming is currently experiencing a renaissance both within research projects in academia and industrial manufacturing processes. One main challenge of such research activities is any improvement of joint strength. In contrast to conventionally joined interference fits, such components can be manufactured without heating or thermal loads. Within framework of the priority program SPP 1640 of the German Research Foundation, a common lateral extrusion process for a solid internal part and an external tube actually is being developed at the Institute for Metal Forming Technology, Stuttgart. Aim of this project is to manufacture a form-closed as well as force-closed joint composed by a high strength external material and a light weight internal material for light-weight components. The present work describes numerical investigations of this process and shows aspects of process development. This includes, among other things, development of a new tool concept, which provides divided punches to determine the influence of different punch motion on the forming and joining process. Spring back behavior, induced residual stress distribution and occurring contact area depending on different material combinations are also investigated. Moreover, the process limits regarding component geometry and force requirement are shown.

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.

Sheet Metal Forming - A New Kind of Forge for the Future

2007 ◽  
Vol 344 ◽  
pp. 9-20 ◽  
Author(s):  
Manfred Geiger ◽  
Marion Merklein
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Elevated Temperatures ◽  
High Strength ◽  
Light Weight ◽  
Influencing Parameters ◽  
General Possibility ◽  
Industrial Relevance ◽  
Weight Structures

Within the last years in sheet metal forming a trend towards forming at elevated temperatures as well as temperature assisted forming technologies can be observed. This development is caused by the increasing need on light and high strength materials in order to fulfill the demands of light weight structures. The decision which kind of temperature assistance is the most useful in order to improve the formability of the material depends on a hugh number of process influencing parameters, like e.g. the material itself, the geometry of the component, the number of forming operations etc.. In this paper the general possibility to separate different temperature assisted forming processes with regard to the used materials will be introduced. The different forming procedures will be explained and discussed. Examples with an industrial relevance are shown.

Formability of High Strength Sheet Metals with Special Regard to the Effect of the Influential Factors on the Forming Limit Diagrams

2015 ◽  
Vol 812 ◽  
pp. 271-275 ◽  
Author(s):  
Miklós Tisza ◽  
Péter Zoltán Kovács ◽  
Zsolt Lukács ◽  
Antal Kiss ◽  
Gaszton Gál
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
High Strength Steels ◽  
High Strength ◽  
Forming Limit ◽  
Experimental Investigations ◽  
Sheet Metals ◽  
Forming Limit Diagrams ◽  
Research Activities

Car manufacturing is one of the main target fields of sheet metal forming: thus sheet metal forming is exposed to the same challenges as the automotive industry. The continuously increasing demand on lower consumption and lower CO2 emission means the highest challenges on materials developments besides design and construction. As a general requirement, the weight reduction and light weight construction principles should be mentioned together with the increased safety prescriptions which require the application of high strength steels. However, the application of high strength steels often leads to formability problems. Forming Limit Diagrams (FLD) are the most appropriate tools to characterize the formability of sheet metals. Theoretical and experimental investigations of forming limit diagrams are in the forefront of todays’ research activities.

Bolts Manufacturing Technology

2017 ◽  
Vol 265 ◽  
pp. 79-85 ◽  
Author(s):  
E.S. Reshetnikova ◽  
D.U. Usatiy ◽  
T.V. Usataya
Keyword(s):  
Metal Forming ◽  
Process Development ◽  
New Technology ◽  
Experimental Studies ◽  
High Strength ◽  
Cold Forming ◽  
Modeling Technology ◽  
New Instrument ◽  
New Process

The urgency of a new process development of cold forming of high-strength flange bolts has been shown in the article. It also points out some shortcomings of existing technologies. To improve the quality of bolts a new instrument design was developed. The research of the working tool identification impact on its resistance and stress-strain state of the workpiece was carry out. The software package DEFORM, designed for process simulation of metal forming is used in the article. The mathematical and computer modeling technology bolt stamping with flange was applied to carry out the study. Based on the conducted theoretical and experimental studies a new technology for manufacturing the flange bolts is patented.

Briefing of CSC and its R & D Activities for Metal Forming

2014 ◽  
Vol 626 ◽  
pp. 576-582
Author(s):  
Shyi Chin Wang
Keyword(s):  
Aluminum Alloys ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Technology Innovation ◽  
High Speed Steel ◽  
High Strength ◽  
Cold Forming ◽  
Research Activities ◽  
Work Rolls

China Steel Corporation was founded in 1971 being the largest integrate steel mill in Taiwan. After several stages of expansion projects, its crude steel production has reached 16.5 million tons annually. CSC has made consistent efforts on its technology innovation mainly carried out by two R & D departments. One of the major tasks of its R & D activities is to establish the advanced technologies for the manufacturing better steels and aluminum alloys as well as product application technology for downstream users. This presentation will mainly brief the research activities of CSC in the field of metal forming including rolling, sheet metal forming and thermal mechanical simulations carried out at Gleeble 3800. Work rolls with continuously variable crown (CVC) were applied to produce hot-rolled strips having precise profile and flatness. Lubrication rolling technology with high speed steel rolls was developed to diminish the wearing of work rolls at hot strip mills. The campaign life of rolling cycle was greatly prolonged. Computer-aided engineering (CAE) simulation technology of sheet metal forming has been established which proved to be an effective way to deal with the sever spring back and breakage of the cold forming of high strength steel automobile parts. Hot stamping has also been developed to support the technology innovation of CSC’s downstream customers. Flow stress and microstructure evolution during hot rolling for aluminum alloys were investigated using a Gleeble 3800 simulator. Both high strength AA5182 for can end and low earing AA3104 for can body aluminum sheets have been successfully developed.

scholarly journals Continuous Production of Pure Titanium with Ultrafine to Nanocrystalline Microstructure

Materials ◽  
2020 ◽  
Vol 13 (2) ◽  
pp. 336 ◽  
Author(s):  
Kateřina Mertová ◽  
Jan Palán ◽  
Michal Duchek ◽  
Tomáš Studecký ◽  
Jan Džugan ◽  
...  
Keyword(s):  
Process Development ◽  
Continuous Production ◽  
Pure Titanium ◽  
Fem Analysis ◽  
High Strength ◽  
Extrusion Process ◽  
Commercial Application ◽  
Angular Pressing ◽  
Continuous Extrusion ◽  
Titanium Grade

This work deals with the application of the Conform SPD (Severe Plastic Deformation) continuous extrusion process for ultrafine to nanostructured pure titanium production. The process has been derived from the Equal Channel Angular Pressing (ECAP) technique but, unlike ECAP, it offers continuous production of high-strength wire. This study describes the Conform SPD process combined with subsequent cold working (rotary swaging technique), its potential for commercial application, and the properties of high-strength wires of pure titanium. High-strength wire of titanium Grade 4 is the product. Titanium Grade 4 reaches ultimate strengths up to 1320 MPa. This value is more than twice the ultimate strength of the unprocessed material. The typical grain size upon processing ranges from 200 to 500 nm. Process development supported by FEM analysis together with detailed microstructure characterization accompanied by mechanical properties investigation is presented.

Microstructure of an extruded rapidly solidified Al-8Fe-2Mo alloy

1986 ◽  
Vol 44 ◽  
pp. 548-549
Author(s):  
W. T. Donlon ◽  
J. E. Allison ◽  
S. Shinozaki
Keyword(s):  
Electron Microscopy ◽  
Automotive Industry ◽  
Fuel Economy ◽  
High Strength ◽  
Al Alloys ◽  
Light Weight ◽  
Thin Sections ◽  
Strength And Durability ◽  
Rapidly Solidified ◽  
Whitney Aircraft

Light weight materials which possess high strength and durability are being utilized by the automotive industry to increase fuel economy. Rapidly solidified (RS) Al alloys are currently being extensively studied for this purpose. In this investigation the microstructure of an extruded Al-8Fe-2Mo alloy, produced by Pratt & Whitney Aircraft, Goverment Products Div. was examined in a JE0L 2000FX AEM. Both electropolished thin sections, and extraction replicas were examined to characterize this material. The consolidation procedure for producing this material included a 9:1 extrusion at 340°C followed by a 16:1 extrusion at 400°C, utilizing RS powders which have also been characterized utilizing electron microscopy.

FEDERATED F150.5

Alloy Digest ◽  
1975 ◽  
Vol 24 (11) ◽  
Keyword(s):  
Fracture Toughness ◽  
Aluminum Alloy ◽  
High Temperature ◽  
Physical Properties ◽  
Tensile Properties ◽  
High Strength ◽  
Heat Treating ◽  
Alloying Elements ◽  
Light Weight ◽  
Temperature Performance

Abstract FEDERATED F150.5 is a heat-treatable aluminum alloy containing silicon and copper as the major alloying elements. It is recommended for high-strength, light-weight, pressure-tight castings. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties as well as fracture toughness. It also includes information on high temperature performance as well as casting, heat treating, machining, and joining. Filing Code: Al-219. Producer or source: Federated Metals Corporation, ASARCO Inc..

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