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

Henneberg, Johannes; Merklein, Marion

doi:10.1016/j.cirpj.2020.08.007

Cited by 5 publications

(3 citation statements)

References 26 publications

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“…Knowing the ultrasonic velocity of the material, a damage parameter D can then be determined by comparing the initial condition with the cold-rolled conditions, cf. Equation (1).…”

Section: Measuring the Ultrasonic Velocitymentioning

confidence: 99%

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Correlating Ultrasonic Velocity in DC04 with Microstructure for Quantification of Ductile Damage

Wackenrohr,

Herbst,

Wöbbeking

et al. 2023

JMMP

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The detection of ductile damage by image-based methods is time-consuming and typically probes only small areas. It is therefore of great interest for various cold forming processes, such as sheet-bulk metal forming, to develop new methods that can be used during the forming process and that enable an efficient detection of ductile damage. In the present study, ductile damage in DC04 was examined using ultrasonic testing. First, different grain sizes were set by heat treatment. Subsequently, the sheet metal was formed by cold rolling. A clear correlation between the average void diameter and the measured ultrasonic velocity could be shown. The ultrasonic velocity showed a clear decrease when the average void size increased because of the increasing forming degree. The ultrasonic measurements were finally employed to calculate a damage parameter D to determine the amount of ductile damage in the microstructure for different grain sizes after cold rolling.

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“…Knowing the ultrasonic velocity of the material, a damage parameter D can then be determined by comparing the initial condition with the cold-rolled conditions, cf. Equation (1).…”

Section: Measuring the Ultrasonic Velocitymentioning

confidence: 99%

“…The process class of sheet-bulk metal forming (SBMF) combines sheet metal forming with bulk forming operations and enables the production of components with integrated functional elements [1]. As a result of cold forming, ductile damage in the form of void formation in the material can occur [2].…”

Section: Introductionmentioning

confidence: 99%

Correlating Ultrasonic Velocity in DC04 with Microstructure for Quantification of Ductile Damage

Wackenrohr,

Herbst,

Wöbbeking

et al. 2023

JMMP

View full text Add to dashboard Cite

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“…Parts with relatively precise dimensions can also be obtained working with small amounts of material poured on precise moulds [2]. Bulk solid parts can be further processed and forced to adopt some more precise shapes by methods like forging, lamination or extrusion [3][4][5]. Details in these resulting parts can be further worked by machining [6], generally resulting in a certain amount of excess material.…”

Section: Introductionmentioning

confidence: 99%

Capacitor Electrical Discharge Consolidation of Metallic Powders—A Review

Aranda

Fernández

Lozano-Pérez

et al. 2021

Metals

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Manufacturing metallic materials from elemental or alloyed powders is an option in many industrial processes. Nevertheless, the traditional powder metallurgy processing including furnace sintering is at times detrimental for the microstructure attained in the powders. Alternative sintering processes based on the use of electricity and the energy obtained by the Joule effect in powder particles can be quick enough to avoid microstructural changes. In particular, when the energy is stored in a capacitor and then discharged, the heating process is extremely quick, lasting milliseconds or even microseconds. This process, generally known as electrical discharge consolidation, has been applied to a wide variety of metallic materials, easily preserving the original microstructure of the powders. Both porous or homogeneous and highly densified material can be obtained, and without losing the desired properties of the consolidated material. A general overview of the process and applications, as well as the results obtained by different research groups around the world, have been reviewed in this manuscript.

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Influence of material in sheet-bulk metal forming from coil

Leicht,

Merklein

2024

Prod. Eng. Res. Devel.

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Sheet-bulk metal forming (SBMF) represents an innovative approach for the efficient manufacturing of functional integrated parts from sheet metal by applying bulk forming processes to sheet metal. It combines the advantages of part weight optimization and process chain shortening. In view of the increasing demand for functionally integrated components, the forming from coil offers an economical possibility to produce high output rates. Nevertheless, an underfilling of functional elements as well as an asymmetric part forming are current challenges. In order to apply SBMF from coil in industrial contexts, it is necessary to understand the causes of these process limits and to develop measures for improving the forming of functional elements and thereby push existing forming limits. In this paper, both a lateral and a backward extrusion process from coil for the forming of internal and external geared SBMF parts are investigated to develop a fundamental process understanding. In a combined numerical-experimental approach, the influence of the flow behavior of different materials as well as the impact of the main material flow direction of the process on the dimensional part accuracy is analyzed. This enables the evaluation of fundamental material-related dependencies and influences regarding the geometrical part accuracy, the mechanical component properties and the tool load for forming of the conventional deep-drawing steel DC04 (t0 = 2 mm), a high-strength steel material (HC260LA) and an aluminum alloy (AA6082 T6). Based on these findings, measures for material flow control are identified and investigated to counteract the challenges of SBMF from coil. These findings permit the identification of potential transferability of the identified cause-effect mechanisms to different processes, component geometries and materials. Thereby, in particular, an increase in coil width as well as lower a strain hardening behavior of the material offers the possibility to improve the geometrical accuracy of the components.

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

Cited by 5 publications

References 26 publications

Correlating Ultrasonic Velocity in DC04 with Microstructure for Quantification of Ductile Damage

Correlating Ultrasonic Velocity in DC04 with Microstructure for Quantification of Ductile Damage

Capacitor Electrical Discharge Consolidation of Metallic Powders—A Review

Influence of material in sheet-bulk metal forming from coil

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