Static and oscillation superimposed ring compression tests with structured and coated tools for Sheet-Bulk Metal Forming

Behrens, Bernd‐Arno; Meijer, Alexander; Stangier, Dominic; Hübner, Sven; Biermann, Dirk; Tillmann, Wolfgang; Rosenbusch, Daniel; Müller, Philipp

doi:10.1016/j.jmapro.2020.04.007

Cited by 12 publications

(6 citation statements)

References 14 publications

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“…It can be seen that to deform the same cup the stress value is much lower than what it was seen with no oscillation cup. This aligns with the previously reported studies [15][16][17][18][19][20][21][22] that the stress/force decreases with oscillation. The maximum von Mises stress achieved in these cups is 202, 210, 213, and 219 MPa with 0.1, 0.25, 0.5, and 1 mm amplitude.…”

Section: Resultssupporting

confidence: 93%

“…It can be seen that the no oscillation strain path is definitely higher than the FLC. As observed earlier 15–22 strain decreases with oscillation. But the FLCs are for the conventional sheet metal forming, however, the FFL curve is used to predict the failure of parts formed by SPIF.…”

Section: Resultssupporting

confidence: 82%

“…15 The tool oscillation method shows the reduction in forming forces due to reduction in friction, softening of the metal, and relaxation of the strain. [15][16][17][18][19][20][21][22] In this paper, the oscillations were created during the SPIF to investigate the deformation behavior. The number of cycles for oscillation with various amplitudes was also studied to see the effect on deformation behavior.…”

Section: Introductionmentioning

confidence: 99%

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Numerical study on the effect of oscillation on the deformation behavior of single point incremental formed part

Nikhare

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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The paper reports the deformation behavior of single point incremental formed part with sheet oscillation. Single point incremental forming is an emerging manufacturing technology. This technology provides the competition to the other innovative technologies such as electric-assisted manufacturing, hydroforming, high-speed forming, etc., to produce the lightweight and highly deformed components. Single point incremental forming is the die-less sheet metal forming process in which the single point tool incrementally forces any single point of sheet metal at any processing time to undergo plastic deformation. In single point incremental forming, the part stays fixed and the tool pin makes the planar and downward motion to shape the part. It has several advantages over the conventional process such as high process flexibility, elimination of die, complex shape, and better formability. Previous literature provides enormous research on the formability of metal during this process, process with various metals and hybrid metals, the influence of various process parameters, but research on the deformation behavior of the part through the oscillation of the tool was limited. In this paper, the single point incremental forming was simulated on ABAQUS finite-element software. The spiral tool path was studied. First, the part was formed without oscillation. Then the oscillation of the sheet with the help of a die and blank holder was set with a frequency to deform the part. The variation of frequency and amplitude was also studied. The formability of the part was analyzed and compared. The deformation, profile shape, strain path, thickness, and force requirement were analyzed and presented. It was found that with lower cycles the maximum stress increases with an increase in amplitude. Also, with an increase in the number of cycles the achieved strain values were lower as compared to the no oscillation case for the same cup height and thus higher deformation is possible with oscillation.

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Section: Resultssupporting

confidence: 93%

Section: Resultssupporting

confidence: 82%

Section: Introductionmentioning

confidence: 99%

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Numerical study on the effect of oscillation on the deformation behavior of single point incremental formed part

Nikhare

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…Thus, superimposed oscillation favors the material flow for DC04. Deviations in the forming behavior in a superimposed oscillation forming between DC04 and DP600 material have already been determined in previous studies [19] but are not yet fully clarified. For the DP600 specimens, no differences in grain size and grain orientation can be detected for oscillation-free and superimposed oscillated pre- The DP600 specimens have a hardness of 186 ± 4 HV in delivery conditions.…”

Section: Metallographicsmentioning

confidence: 87%

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

Behrens

Hübner

Rosenbusch

et al. 2020

Metals

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Within the scope of the transregional collaborative research centre TCRC73, the effects of an oscillation superimposed forming process for the production of a demonstrator component are investigated. Previous studies in this field were limited to a consideration of the process-related parameters such as the influence of the plastic work and the friction or the component-related parameters such as the influence of the surface quality and the mold filling. This research concentrates on the consideration of the mechanical vibration resistance of components that were manufactured superimposed oscillated. For this purpose, Wöhler tests are conducted in which the fatigue strength of superimposed oscillation pre-stretched test samples and oscillation-free pre-stretched test samples are investigated. First, Wöhler curves are generated in the tensile threshold range for tensile samples made out of the steels DC04 and DP600. Subsequently, tensile specimens are pre-stretched superimposed oscillated and oscillation-free. These specimens are subjected to a tensile threshold load until they break. The influence of the superimposed oscillation forming on the long-term fatigue of components is derived from the comparison of the bearable load cycles. Investigations of the microstructure of the specimens are conducted in order to draw conclusions about the influence on the long-term strength.

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“…Therefore, high-feed m suitable for controlling surface properties, e.g., roughness and residual stress complex and especially on large surface areas [23]. [31] and (b) micromilling [32].…”

Section: Materials and Surface Modificationmentioning

confidence: 99%

Analysis of the Influence of Surface Modifications on the Fatigue Behavior of Hot Work Tool Steel Components

Wild¹,

Platt

Biermann

et al. 2021

Materials

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Hot work tool steels (HWS) are widely used for high performance components as dies and molds in hot forging processes, where extreme process-related mechanical and thermal loads limit tool life. With the functionalizing and modification of tool surfaces with tailored surfaces, a promising approach is given to provide material flow control resulting in the efficient die filling of cavities while reducing the process forces. In terms of fatigue properties, the influence of surface modifications on surface integrity is insufficiently studied. Therefore, the potential of the machining processes of high-feed milling, micromilling and grinding with regard to the implications on the fatigue strength of components made of HWS (AISI H11) hardened to 50 ± 1 HRC was investigated. For this purpose, the machined surfaces were characterized in terms of surface topography and residual stress state to determine the surface integrity. In order to analyze the resulting fatigue behavior as a result of the machining processes, a rotating bending test was performed. The fracture surfaces were investigated using fractographic analysis to define the initiation area and to identify the source of failure. The investigations showed a significant influence of the machining-induced surface integrity and, in particular, the induced residual stress state on the fatigue properties of components made of HWS.

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Static and oscillation superimposed ring compression tests with structured and coated tools for Sheet-Bulk Metal Forming

Cited by 12 publications

References 14 publications

Numerical study on the effect of oscillation on the deformation behavior of single point incremental formed part

Numerical study on the effect of oscillation on the deformation behavior of single point incremental formed part

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

Analysis of the Influence of Surface Modifications on the Fatigue Behavior of Hot Work Tool Steel Components

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