Manufacturing of functional elements by sheet-bulk metal forming processes

Gröbel, Daniel; Schulte, Robert; Hildenbrand, Philipp; Lechner, Michael; Engel, Ulf; Sieczkarek, Peter; Wernicke, Sebastian; Gies, S.; Tekkaya, A. Erman; Behrens, Bernd‐Arno; Hübner, Sven; Vucetic, Milan; Koch, Sergej; Merklein, Marion

doi:10.1007/s11740-016-0662-y

Cited by 34 publications

(11 citation statements)

References 12 publications

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“…In order to displace the same material volume in both processes, the blind cavity has a targeted diameter of 11.1 mm and an edge radius of 0.5 mm. The workpiece material used in both processes is the mild deep-drawing steel 1.0338 due to its established usage in SBMF [23] with an initial sheet thickness of 2 mm and a coil width of 30 mm. The geometries of the active tool parts are derived from the components and used in the tool systems shown in Figure 3.…”

Section: Process Setupmentioning

confidence: 99%

Measures for controlling the material flow when extruding sheet-bulk metal forming parts from coil

Henneberg

Merklein

2020

Manufacturing Rev.

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The increasing demand for lightweight design requires functional integration. This poses challenges to conventional manufacturing processes due to the rising geometrical complexity of components. The application of bulk forming operations to sheet metal, named sheet-bulk metal forming (SBMF), is one approach to overcome these challenges. Currently, mainly pre-cut blanks are applied in research of SBMF. Production from coil, in contrast, would combine the advantages of SBMF with the advantages of manufacturing from a coil regarding high output quantity. To research SBMF from coil, a lateral and a backward extrusion process are set up. In addition to a reduced geometrical accuracy of the parts, which is known from SBMF of pre-cut blanks, an anisotropic material flow is identified as a coil-specific challenge. The aim of this research is to investigate measures that extend the forming limits by means of a material flow control. For this purpose, a combined numerical-experimental approach is applied in order to analyze and evaluate an adaption of the width of the coil, the feed width, and the local friction as measures for material flow control. Particularly local adaptation of friction by means of modified tool surfaces reduces the anisotropic material flow and improves the geometrical accuracy of the parts.

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Section: Process Setupmentioning

confidence: 99%

Measures for controlling the material flow when extruding sheet-bulk metal forming parts from coil

Henneberg

Merklein

2020

Manufacturing Rev.

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“…Therefore, a comprehensive mechanical characterization of the utilized sheet materials, a bainitic steel (BS600) and an innovative high-manganese steel (H-Mn) with an initial thicknesses of t 0 = 2 mm is essential. Gröbel et al [13] numerically determined the effective strain ϕ resulting in SBMF components to be larger than 4. To obtain a more precise extrapolation of the flow curves in-plane torsion tests, in accordance with Traphöner et al [14], are carried out.…”

Section: Mechanical Characterizationmentioning

confidence: 99%

Properties of Components with Incrementally Formed Gears

Wernicke

Sieczkarek

Gies

et al. 2019

Metals

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The process class of sheet-bulk metal forming (SBMF) involves several advantages for the manufacture of functional components. Its incremental variant (iSBMF) enables a very flexible dimensioning of components. To treat the unfavorable manufacturing time of the incremental approach, this investigation is focused on an alternative process route using rotating forming tools, which decrease the process time significantly. After an analysis of the mechanical properties as well as the micro- and macroscopic surface quality, a quasi-static benchmark test was performed. Normalized by the weight of the component, gears manufactured by iSBMF and BS600 steel presented the same load capacity as gears manufactured by blanking with subsequent hardening. Here, using innovative high strength steels with a significant strain hardening behavior like high manganese steels enables for weight-reduced gears.

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“…Recently, a new sheet metal forming concept, applying compressive stress to a sheet to obtain a sheet-shaped part with high-quality functional elements, was proposed [11].…”

Section: Introductionmentioning

confidence: 99%

Reduction of die roll height in duplex gears through a sheet-bulk metal forming method

et al. 2019

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In the existing shearing processes for fabricating parts such as duplex gears, die roll is difficult to avoid. Accordingly, a method based on sheet-bulk metal forming for fabricating a duplex gear with extremely small die roll in one stroke is proposed in the current work. The process could be divided into three stages according to the forming features: upsetting and shearing stage, lateral extrusion stage, and local filling stage. The die roll appeared in the shearing stage, which could be reduced in the subsequent extrusion and local filling stages. To reveal the underground mechanism, material flows under two situations, as a key factor to influence the forming quality, were compared and investigated. The results revealed that by controlling material flow, one could avoid the defects and reduce the die roll.

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Manufacturing of functional elements by sheet-bulk metal forming processes

Cited by 34 publications

References 12 publications

Measures for controlling the material flow when extruding sheet-bulk metal forming parts from coil

Measures for controlling the material flow when extruding sheet-bulk metal forming parts from coil

Properties of Components with Incrementally Formed Gears

Reduction of die roll height in duplex gears through a sheet-bulk metal forming method

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