Investigation on blasted tool surfaces as a measure for material flow control in sheet-bulk metal forming

Merklein, Marion; Löffler, Maria; Gröbel, Daniel; Henneberg, Johannes

doi:10.1051/mfreview/2019012

Cited by 3 publications

(2 citation statements)

References 14 publications

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“…Opposing the alternative methods for modifying tool surfaces, such as milling or grinding, blasting offers a high degree of geometrical freedom regarding the treated surfaces. Investigations have shown that abrasive blasting in an upsetting process has significant potential for controlling the material flow [29]. In Figure 17, the surfaces used in forming experiments for this study are shown.…”

Section: Tribological Approachmentioning

confidence: 99%

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Pilz¹,

Henneberg²,

Merklein³

2020

Manufacturing Rev.

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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. This is an Open Access article distributed under the terms of the Creative Commons Attribution License (https://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

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Section: Tribological Approachmentioning

confidence: 99%

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Pilz¹,

Henneberg²,

Merklein³

2020

Manufacturing Rev.

Self Cite

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“…Hereby, the adjustment of the surface roughness plays an important role, as it is directly linked to the resulting friction and the material flow of the process [3]. Through the establishment of a beneficial friction gradient, which means the surface roughening and smoothening in certain tool areas, an improvement of the process result while maintaining acceptable process forces and respectively tool loads can be achieved [4]. To further analyse tailored surfaces, two variants of modifications are investigated within this study.…”

Section: Introductionmentioning

confidence: 99%

Analysis of the Modification of Tool Surfaces by Abrasive Blasting and Laser Polishing

Wild

Bestenlehrer²,

Merklein

2020

DDF

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The surface treatment of tools plays an important role for the operational behaviour of forming processes. Up to now, industrial standard is the manual finishing of tool surfaces, which can lead to a varying quality of the surface finish and therefore influence the tool service life and the forming results. One method to perform the polishing operation automatically is to remelt the top layer of materials by laser polishing. This is accompanied by a considerable change in the material properties in this zone. Therefore, the effect of laser polishing with respect to the local modification of the tool surface is investigated in this study. The results of the investigations reveal that a precise adjustment of the laser parameters is required in order to reduce the roughness of the surface. The heat input also leads to a significant influence on the microstructure of the material. In this study laser polishing remelts the material up to a depth of approximately 20 µm. Furthermore, it can be observed that the heat input during the process results in a heat affected zone of up to a depth of 30 µm. As a contrast to laser polishing, abrasive blasting is investigated as a roughness increasing surface modification.

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Investigation on extrusion processes in sheet-bulk metal forming from coil

Henneberg¹,

Merklein²

2020

CIRP Journal of Manufacturing Science and Technology

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Investigation on blasted tool surfaces as a measure for material flow control in sheet-bulk metal forming

Cited by 3 publications

References 14 publications

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Analysis of the Modification of Tool Surfaces by Abrasive Blasting and Laser Polishing

Investigation on extrusion processes in sheet-bulk metal forming from coil

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