Metal forming beyond shaping: Predicting and setting product properties

Tekkaya, A. Erman; Allwood, Julian M.; Bariani, Paolo Francesco; Bruschi, Stefania; Cao, Jian; Gramlich, Sebastian; Groche, Peter; Hirt, Gerhard; Ishikawa, Takashi; Löbbe, Christian; Lueg‐Althoff, J.; Merklein, Marion; Misiolek, W.Z.; Pietrzyk, M.; Shivpuri, Rajiv; Ye, Jun

doi:10.1016/j.cirp.2015.05.001

Cited by 134 publications

(35 citation statements)

References 171 publications

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“…They allow the entire product to be modeled by determining geometric and material properties. Material properties include mechanical, surface and physical properties of the product . Dependent properties, such as the stiffness of a coil spring, depend on independent product properties, such as the Young's modulus of the chosen material and the length of the coil spring, Fig .…”

Section: Design Pattern Matrix: Finding Manufacturing‐integrated Prodmentioning

confidence: 99%

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Manufacturing‐integrated product solutions: Design support between product function and manufacturing processes

Roos

Wagner

Martins

et al. 2017

Materialwissenschaft Werkst

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With the help of new design tools, manufacturing‐integrated solutions can be generated that concurrently consider function and process. Based on the design pattern matrix, solution elements can be developed that realize the product function by systematically utilizing manufacturing‐induced properties. The developed manufacturing‐integrated product solutions are refined using computer‐aided methods (feature‐based modeling and information modeling). A product embodiment is generated that is specifically tailored to the chosen manufacturing technology. An integrated information model allows the introduced tools to be used throughout the entire development process. The example of a linear flow split snap‐fit fastening illustrates how the tools beneficially interact and realize manufacturing potential, resulting in an innovative product design.

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Section: Design Pattern Matrix: Finding Manufacturing‐integrated Prodmentioning

confidence: 99%

“…Linear flow splitting, a cold forming technology, is used to produce technical products with manufacturing‐induced design elements that are characterized by integral bifurcations and modifications in hardness, strength and microstructural conditions, Fig . [, ].…”

Section: Design Pattern Matrix: Finding Manufacturing‐integrated Prodmentioning

confidence: 99%

Manufacturing‐integrated product solutions: Design support between product function and manufacturing processes

Roos

Wagner

Martins

et al. 2017

Materialwissenschaft Werkst

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“…These differences may be relevant for predicting and setting the final properties of the disk gear [14] but can be easily overcome if the product is subject to induction tempering after being formed.…”

Section: Fabrication Of Sound Disk Gears By Incremental Sheet-bulk Mementioning

confidence: 99%

Incipient and repeatable plastic flow in incremental sheet-bulk forming of gears

Sieczkarek

Wernicke

Gies

et al. 2016

Int J Adv Manuf Technol

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This paper analyses the differences between incipient and repeatable material flow in the incremental sheet-bulk metal forming (SBMF) of gears produced by indentation along the direction perpendicular to the sheet thickness. The underfilling of the punch cavity during the first indentation, which prevents the production of sound disk gears, is explained on the basis of constrained material flow under material strain hardening. A solution based on the utilization of a tailored disk blank is proposed to overcome this defect. The geometry of the tailored disk blank is determined by means of finite element analysis, and the overall methodology involved material characterization and experimentation with DC04 mild steel. The discussion on the extent of the plastic deformation region under constrained and free-material flow during indentation is complemented by experimental results obtained with a flat punch in rectangular sheet blanks of aluminium EN AW-1050A.

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“…In addition, strain induced texture will influence the local elastic behavior and residual stresses can be expected. In order to assess the performance of profiles produced by linear flow splitting or linear bend splitting or to achieve a benefit from the manufacturing‐induced mechanical properties by integrating them into the product development process, local properties of profiles have to be considered with respect to the ideal design of a bifurcated profile . This work aims to give an overview about characteristic mechanical properties of linear flow splitting and linear bend splitting profiles and highlights the correlation between the manufacturing process and the correlating microstructural changes in the material.…”

Section: Introductionmentioning

confidence: 99%

Manufacturing‐induced material properties of linear flow split and linear bend split profiles

Bruder

Ahmels

Niehuesbernd

et al. 2017

Materialwissenschaft Werkst

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In this work the two massive forming processes linear flow splitting and linear bend splitting, which generate profiles from sheet metal, are evaluated with respect to characteristic manufacturing‐induced material properties of the produced parts. Resulting microstructural features such as grain size and shape as well as crystallographic textures are linked to mechanical properties such as strength, ductility and anisotropic elasticity and general rules for their evolution are defined. Residual stress distributions are detailed and discussed with regard to the causing geometrical and forming process related aspects. The aim of this paper is to give a comprehensive overview of the properties of profiles produced by linear flow splitting and linear bend splitting and to illustrate general rules for their evolution in order to provide guidelines for an optimized product development process which allows a beneficial use of the manufacturing‐induced properties.

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Metal forming beyond shaping: Predicting and setting product properties

Cited by 134 publications

References 171 publications

Manufacturing‐integrated product solutions: Design support between product function and manufacturing processes

Manufacturing‐integrated product solutions: Design support between product function and manufacturing processes

Incipient and repeatable plastic flow in incremental sheet-bulk forming of gears

Manufacturing‐induced material properties of linear flow split and linear bend split profiles

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