Investigations and Approaches on Material Flow of Non-uniform Arranged Cavities in Sheet Bulk Metal Forming Processes

Gröbel, Daniel; Koch, Johannes; Vierzigmann, Hans Ulrich; Engel, Ulf; Merklein, Marion

doi:10.1016/j.proeng.2014.10.013

Cited by 15 publications

(10 citation statements)

References 4 publications

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“…In the example above, the maximum possible reinforcement regarding the ultimate compressive strength of the tool steel ASP2023 (1.3344) is utilized. However, simulated results with a validated simulation model [12] show, that tensile stresses can locally reach values of up to 1,500 MPa despite using the relatively low strength steel DC04 of t 0 = 3 mm, which is the maximum sheet thickness formed by this process, initial thickness and a punch stroke of t = 2.7 mm. Hence, especially with high strength materials, available tool load will limit the total process stroke and therefore the maximum possible element dimensions.…”

Section: Forward Extrusionmentioning

confidence: 98%

“…This process variant has been firstly described in reference [11] in combination with deep drawing and has been extended in reference [12] with the introduction of geometrically differing elements to increase the components complexity. In order to perform the forming operation, a circular blank is placed centrally on the die.…”

Section: Forward Extrusionmentioning

confidence: 99%

“…The shape is dependent on the material flow in the cavity itself, which in turn is dependent on the geometrical shape of the cavities [12]. Besides individual die filling, the material flow is of importance in regard to the resulting macroscopic blank geometry, the bulging of the blank when forming without a counterpunch.…”

Section: Forward Extrusionmentioning

confidence: 99%

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Innovative approaches for controlling the material flow in sheet-bulk metal forming processes

et al. 2016

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-Using sheet-bulk metal forming processes the application of bulk forming operations on sheet metals enables the manufacturing of functional components with local wall thickness variations. As these processes come along with a two-and three-dimensional material flow, the control of the material flow is crucial for ensuring a proper filling of functional elements and thus ensuring the components quality. Controlling the material flow can be achieved by different solutions: the local adaption of tribological conditions and the application of process adapted semi-finished parts. In this paper, both solutions as well as their general qualification in two sheet-bulk metal forming processes are presented.

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Section: Forward Extrusionmentioning

confidence: 98%

Section: Forward Extrusionmentioning

confidence: 99%

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Innovative approaches for controlling the material flow in sheet-bulk metal forming processes

et al. 2016

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“…Both processes are modelled by holding planes on the top and bottom of the dies and symmetry planes at the edge of the 17°s egments. This reduces the calculation time while the findings and quality remain constant [19]. One challenge of modelling SBMF processes in simulation is the typical scale conflict between functional-element dimensions and the overall size of the workpiece [19].…”

Section: Setupmentioning

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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“…The radial material flow leads to a bulging of the sheet in the centre and simultaneous insufficient filling of the tool moulds. Current research revealed that this effect is dependent on the chosen geometry of the cavity in question, as well as on the arrangement of the moulds [24].…”

Section: Boundary Conditions For Presented Sheet-bulk Metal Forming Pmentioning

confidence: 99%

Sheet-bulk metal forming – forming of functional components from sheet metals

Merklein

Gröbel

Löffler

et al. 2015

MATEC Web of Conferences

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Abstract. The paper gives an overview on the application of sheet-bulk metal forming operations in both scientific and industrial environment. Beginning with the need for an innovative forming technology, the definition of this new process class is introduced. The rising challenges of the application of bulk metal forming operations on sheet metals are presented and the demand on a holistic investigation of this topic is motivated. With the help of examples from established production processes, the latest state of technology and the lack on fundamental knowledge is shown. Furthermore, perspectives regarding new research topics within sheet-bulk metal forming are presented. These focus on processing strategies to improve the quality of functional components by the application of processadapted semi-finished products as well as the local adaption of the tribological system.

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Investigations and Approaches on Material Flow of Non-uniform Arranged Cavities in Sheet Bulk Metal Forming Processes

Cited by 15 publications

References 4 publications

Innovative approaches for controlling the material flow in sheet-bulk metal forming processes

Innovative approaches for controlling the material flow in sheet-bulk metal forming processes

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

Sheet-bulk metal forming – forming of functional components from sheet metals

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