Due to the ongoing technological development, the demand for geometrically complicated high performance parts with great functional density is increasing. Often, the use of sheet metal is a beneficial approach in manufacturing technology to meet the requirements on components regarding material strength and lightweight construction goals. The forming of therefore required complex sheet metal part geometries with integrated functional elements cause the need for a three dimensional material flow. Sheet-bulk metal forming, characterized by the application of bulk forming operations on sheet metals, is a suitable approach to produce such components. A challenge is the material flow control, resulting in an insufficient die filling of the functional elements. The use of tailored blanks with a defined sheet thickness distribution is an auspicious approach to face this challenge in subsequent forming processes. In the presented work, semi-finished products with a continuous thickness profile manufactured by orbital forming are applied in a full forward extrusion process. By an additional implementation of a heat treatment, the tailored blanks undergo a recrystallization process that causes a softening of the strain hardened material. In this paper, the potential of a heat treatment in the process class of sheet-bulk metal forming is shown by characterizing the geometrical and mechanical properties of the functional components by applying the mild deep drawing steel DC04 with an initial sheet thickness of t0 = 2.0 mm.
Defined surface micrcotextures offer potential for the friction reduction in elastohydrodynamic contacts and can thus increase the energy efficiency of technical systems. The production of prostheses, where microtextured surfaces can provide anti-bacterial effects is another application area. To manufacture these components economically in large quantities, forming processes are to be aimed at. Since lightweight parts are crucial in most application areas, the forming of sheet metal is the subject of current research. A major aspect of the presented investigation is the behavior of tool materials for the production of such microtextured sheet metal parts. Applying microtextures of varying geometries to the tools is a key challenge. Limitations in the accuracy of electrical discharge machining processes for the fabrication of micro cylinders, prisms and cuboids are therefore analyzed on the high-speed steels 1.3343 and 1.3244. In addition, the tool surfaces are characterized regarding their friction properties with case hardening steel as a contact partner. In this paper, the tool friction is analyzed for the steel 1.7131 (16MnCr5) with an initial sheet thickness of t0 = 2.4 mm, which is often utilized for high-wear applications due to its high strength and toughness. In this context, the friction behavior of the wax-containing lubricant Beruforge 150 DL made for bulk forming processes is compared with zinc-free high-performance lubricants Raziol CLF 65-400 of varying viscosity.
In industrial sectors like medical and automotive engineering, the demand for metal components with a high function integration brings conventional production technologies to their limits. This motivates research on innovative processes, which can meet the present requirements on fabricated parts and consequently also the demands on the applied manufacturing process. Part-sided, a high strength, narrow dimensional tolerances and a large functionality is often desired. In addition, an economical component production calls for processes with high material utilization as well as the achievement of short cycle times. The process class of sheet-bulk metal forming, characterized by the application of bulk forming operations on sheet metal, offers the potential to meet these requirements. Currently, sheet-bulk metal forming is mainly used for the fabrication of components with functional elements of macroscopic size. However, microscopic elements and micro-textured surfaces are of high interest for applications in prosthetics and automotive engineering. The objective of this study is therefore to develop an application-oriented method for the design, production and testing of 16MnCr5 metal components, manufactured by a combined process of sheet-bulk metal forming, creating a defined microstructure on the surface. Since the selection of a suitable texture layout and geometry is crucial for tribological optimization, these are designed for their application using numerical elastohydrodynamic lubricant simulations. The contact conditions occurring in the application are modelled as realistically as possible so that texture designs suitable for production can subsequently be compared in test bench trials. It is shown that the tappets produced by forming technology can be efficiently investigated with the test rig presented.
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