Numerical and Experimental Investigations of Multistage Sheet-Bulk Metal Forming Process with Compound Press Tools

Behrens, Bernd‐Arno; Bouguecha, Anas; Vucetic, Milan; Hübner, Sven; Rosenbusch, Daniel; Koch, Sergej

doi:10.4028/www.scientific.net/kem.651-653.1153

Cited by 27 publications

(9 citation statements)

References 8 publications

(10 reference statements)

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“…In the second stage the flange-forming and wall ironing are performed. The third stage of the new SBMF process is used for the calibration of the internal and external toothing [1]. The active tool elements of the individual stages were integrated in a modular tool system [2].…”

Section: Tools and Experimental Results Of A New Sbmf Processmentioning

confidence: 99%

Metrological solutions for an adapted inspection of parts and tools of a sheet-bulk metal forming process

Matthias¹,

Loderer²,

Koch³

et al. 2015

Prod. Eng. Res. Devel.

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Processes of the new production technology sheet-bulk metal forming allow a fast and efficient nearnet-shape forming of highly complex parts. Thus the need of energy and raw material as well as the production cycle time can be reduced. In order to guarantee these advantages by avoiding scrap and moreover to ensure the parts' geometrical requirements, production-related metrological solutions for an adapted inspection of parts and tools of sheet-bulk forming processes have to be developed. To fulfill the demands of the differing measuring tasks two prototypical measurement solutions are under development: a multi-scale multi-sensor fringe projection system allows for holistic inspections in feature adapted resolutions, whereas a fiberscopic fringe projection system captures the forming tool partly between forming steps. For the purpose of evaluating the metrological solutions' capabilities of capturing the geometry of filigree structures a comparison of both systems is presented in this work. To guarantee realistic results, the performed measuring tasks have to be comparable to the areas of applications both systems were designed for. During the development of the measuring systems the emphasis was put on the inspection of small complex geometries. These are most challenging for fast and reliable optical inspection under productionrelated conditions. By considering measurements of calibrated standards on the one side as well as of measuring tasks resulting out of real sheet-bulk metal forming processes on the other side a realistic comparison is assured. Next to the measuring systems' performances also an approach for combining the measurement data of both metrological solutions is shown. By combining the advantages of both measuring systems, highly detailed information for further interpretations of the forming processes can be provided.

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Section: Tools and Experimental Results Of A New Sbmf Processmentioning

confidence: 99%

Metrological solutions for an adapted inspection of parts and tools of a sheet-bulk metal forming process

Matthias¹,

Loderer²,

Koch³

et al. 2015

Prod. Eng. Res. Devel.

Self Cite

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“…Due to the incomplete mould filling of the internal gearing in the second stage, it is calibrated in the third stage. In order to reduce the process development time, FE simulations of single stages were conducted and analysed [11]. To optimize the material flow and to reduce forming force in the process, tool parameters were modified on the basis of plane-strain compression tests.…”

Section: Forming Processmentioning

confidence: 99%

“…In this process, superimposed oscillation forming is used in the second operation step for the forming of the internal gearing. This process modification led to positive effects in terms of improved mold filling and reduced forming forces [11].…”

Section: Introductionmentioning

confidence: 99%

Influence of Tailored Surfaces and Superimposed-Oscillation on Sheet-Bulk Metal Forming Operations

Behrens

Tillmann

Biermann

et al. 2020

JMMP

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Producing complex sheet metal components in fewer process steps motivated the development of the innovative forming process called sheet-bulk metal forming (SBMF). In this process, sheet metal forming and bulk-metal forming are combined to create a unique forming process in which a component with external and internal gearing is produced in three production steps. However, the high degrees of deformation that occur using high-strength steels and the number of different process steps result in high process forces, strongly limiting the service life of tools. To reduce the forming force during SBMF processes, tool and process modifications were investigated. Therefore, plane-strain compression tests were conducted to examine the influence of a CrAlN PVD coating and tailored surfaces produced by high-feed milling (HF) of tool-active elements on the material flow of the specimens. In addition to the tool-sided modifications, the influence of an oscillation overlay during the forming process was investigated. Based on the results of the compression tests, the surfaces of the active tool elements of the SBMF process were modified in order to transfer the basic experimental results to the production of a functional component. The friction is thus adapted locally in the SBMF process.

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“…To avoid cost-intensive real experiments, decoupled variant simulations are used [12]. Simufact.forming 14.0 is a special forming software which is often used in SBMF [13].…”

Section: Numerical Modelmentioning

confidence: 99%

Influence of component design on extrusion processes in sheet-bulk metal forming

Pilz

Merklein

2019

Int J Mater Form

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Nowadays, the functional integration of workpieces challenges existing forming processes. The combination of established forming processeslike sheet metal and bulk formingoffers the possibility to counter this issue. The application of bulk forming operations on sheet metal semi-finished products, also called sheet-bulk metal forming (SBMF), is an innovative approach. The potential of SBMF cannot be fully exploited, as there are no recommendations in terms of workpiece design and layout influence on the process result. Therefore, this paper focuses on the analysis of semi-finished products and component design parameters on resulting part and process properties in two extrusion processes in SBMF. The investigation is based on a combined numerical and experimental approach. It is shown that the investigated design parameters, in addition to the achievable dimensional accuracy, substantially influence the occurring tool loads as well as the required process forces.

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Numerical and Experimental Investigations of Multistage Sheet-Bulk Metal Forming Process with Compound Press Tools

Cited by 27 publications

References 8 publications

Metrological solutions for an adapted inspection of parts and tools of a sheet-bulk metal forming process

Metrological solutions for an adapted inspection of parts and tools of a sheet-bulk metal forming process

Influence of Tailored Surfaces and Superimposed-Oscillation on Sheet-Bulk Metal Forming Operations

Influence of component design on extrusion processes in sheet-bulk metal forming

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