New Multistage Sheet-Bulk Metal Forming Process Using Oscillating Tools

Abstract

A new sheet-bulk metal forming process for the production of bulk components out of a flat sheet has been developed. Superimposed oscillation has been applied to the new process. By this means, process limits regarding better mould filling were expanded, and forming forces could be reduced. In order to investigate the effects of superimposed oscillation on material behaviour, plane strain and ring compression tests were carried out. The superimposed oscillated plane strain compression test showed a reduction in biaxial flow stress and thus in plastic work. Furthermore, reduced friction and roughness were verified in ring compression tests using superimposed oscillation.

Investigations of the Influence of a Superimposed Oscillation on the Fatigue Strength

“…In this research, the effects of a superimposed oscillated pre-stretching on the fatigue strength, strain hardening, and structural properties of tensile test specimens made of the materials DC04 and DP600 were investigated. Since a superimposed oscillation has a high potential according to an extension of forming limits [13], a better understanding of the effects of a superimposed oscillation on the fatigue strength and strain hardening is of high importance. It was found that the fatigue strength behavior, strain hardening, and the influence on the microstructure of the materials DC04 and DP600 can be influenced differently by a superimposed oscillation.…”

“…Since the high potential of superimposed oscillated-forming processes on effects such as increasing the surface quality [12] and improving the form-filling [13] of components has been demonstrated in previous studies, this technology has promising application possibilities. Especially in the new technology of sheet-bulk metal forming, which aims at the production of complex functional components with secondary forming elements made of thin sheets [14], superimposed oscillated forming offers the interesting possibility of extending the production limits of this technology.…”

Fringe Projection Profilometry in Production Metrology: A Multi-Scale Comparison in Sheet-Bulk Metal Forming

“… Multi-stage sheet-bulk metal forming (SBMF) process for the production of components with rotationally symmetrical external gearing [ 5 ]. ( a ) Initial state; ( b ) Deep drawing; ( c ) Compression and shear cut.…”

“…SBMF processes combine numerous methods of forming technology. As an example of such a process, a stage sequence for the production of a component with internal and external gearing is shown in Figure 1 [ 5 ]. In this process, a cup is first deep-drawn from a 4 mm wide round blank.…”

“…Achievable geometrical, topographical, and mechanical properties for the production of process component 1 were studied and analyzed in detail by Koch [ 6 ]. Additionally, tailored surfaces for the specific friction adjustment on tool surfaces were installed [ 7 ], and the influence of oscillating tool elements on increasing the material flow [ 5 ] and on improving the surface quality [ 8 ] was investigated. The produced gear component with a total of 38 teeth is shown in Figure 2 a.…”