Sheet-Bulk Metal Forming of Symmetric and Asymmetric Parts

Abstract

The unique process of sheet-bulk metal forming (SBMF) represents a combination of sheet and bulk metal forming by inducing a three-dimensional material flow in sheet metals in a single forming stage. Within this paper two different applications of sheet-bulk metal forming are demonstrated. Hereby two different combined drawing and upsetting processes to realize parts with symmetrically and asymmetrically arranged functional elements are analysed. Finally, this contribution introduces a new machine technique which provides an improvement of the working accuracy of a forming machine and thus has a positive influence on the parts quality. The idea is to use electromagnetic ram guidance to counteract the displacement of the ram due to horizontal forming forces while forming of asymmetric parts.

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

“…The accurate production of asymmetric parts by means of forming technology is a challenging task due to the existence of horizontal process forces and therewith occurring ram displacement [4,17,27]. For investigations of the process-machine interaction while forming asymmetric parts, a tool combining deep drawing and coining gearing elements by means of SBMF was realized [17].…”

“…For investigations of the process-machine interaction while forming asymmetric parts, a tool combining deep drawing and coining gearing elements by means of SBMF was realized [17]. Figure 4a depicts the tool.…”

“…Since the gearing elements are rotated by 30°to the bolster plate, horizontal process forces occur while coining in bottom dead center (BDC). Horizontal process forces lead to ram tilt and horizontal ram displacement as described in [17,18], and have a negative impact on the part quality as presented in Sect. 4.4.…”

“…6). The use of an electromagnetic system to avoid horizontal ram displacement by means of opposing electromagnetic forces was presented in [17] first, design and optimisation of the electromagnetic system in [6].…”

“…The insufficient mold filling is a result of the horizontal ram displacement while coining the gearing elements [17]. By realizing the electromagnetic system as described in Sect.…”