Blechmassivumformung von Funktionsbauteilen aus Bandmaterial

Sheet-bulk metal forming as an application of bulk forming processes to sheet metal combines the advantages of sheet and bulk metal forming. Thin-walled and thus lightweight components with integrated functional elements, such as gears or pins, are formed from flat semi-finished products by means of a three-dimensional material flow. This meets the goal of lightweight construction and realizes systems with sustainable application behavior. In order to further increase the efficiency of sheet-bulk metal forming, the production of functional components from coil is being researched as part of the work. Forming from coil increases the output quantity compared to manufacturing with pre-cut blanks. The objective of this work is to develop a basic process understanding for the forming of functional components from coil. In this context, the coil-specific challenges and their causes with regard to the material flow and the tool loads are identified. Based on this, workpiece-, process- and tool-sided measures for material flow control are researched in order to extend the process limits. In the case of wear-critical measures, their application behavior is investigated in tool life tests and the suitability of the measures for the production of a high number of components is demonstrated. Finally, the results of the work are used to derive application-related recommendations for the sheet-bulk metal forming of functional components made from coil.Die Blechmassivumformung als Anwendung von Massivumformverfahren auf Blech vereint die Vorteile der Blech- und Massivumformung. Aus flächigen Halbzeugen werden dünnwandige und folglich leichte Bauteile mit integrierten Funktionselementen, wie Verzahnungen oder Zapfen, durch einen dreidimensionalen Stofffluss ausgeformt. Hierdurch werden dem Ziel des Leichtbaus entsprochen und Systeme mit nachhaltigem Einsatzverhalten realisiert. Um die Effizienz der Blechmassivumformung weiter zu steigern, wird im Rahmen der Arbeit das Fertigen von Funktionsbauteilen aus Bandmaterial erforscht. Durch die Umformung vom Band wird die Ausbringungsmenge im Vergleich zu einer Fertigung aus vorbeschnittenen Ronden gesteigert. Zielsetzung der Arbeit ist es, ein grundlegendes Prozessverständnis für die Blechmassivumformung von Funktionsbauteilen aus Bandmaterial zu erarbeiten. Hierbei werden die bandspezifischen Herausforderungen und deren Ursachen bezüglich des Werkstoffflusses und den Werkzeugbeanspruchungen identifiziert. Aufbauend hierauf werden zur Erweiterung der Prozessgrenzen werkstück-, prozess- sowie werkzeugseitige Maßnahmen zur Stoffflusssteuerung bei der Umformung von Bandmaterial erforscht. Bei verschleißkritischen Maßnahmen wird deren Einsatzverhalten in Standmengenversuchen analysiert und die Eignung der Maßnahmen für die Fertigung einer hohen Stückzahl an Bauteilen nachgewiesen. Aus den Ergebnissen der Arbeit werden abschließend anwendungsbezogene Hinweise für die Blechmassivumformung von Funktionsbauteilen aus Bandmaterial abgeleitet

Investigation on blasted tool surfaces as a measure for material flow control in sheet-bulk metal forming

Highly integrated and closely tolerated functional components can be produced by sheet-bulk metal forming which is the application of bulk forming operations on sheet metal. These processes are characterized by a successive and/or simultaneous occurrence of different load conditions which reduce the geometrical accuracy of the parts. One challenge within sheet-bulk metal forming is the identification of methods to control the material flow to improve the product quality. A suitable approach is the local modification of the tribological conditions. Within this study, requirements regarding the needed adaption of the tribological system for a specific process were defined by numerical investigations. The results reveal that a local increase of the friction leads to an improved geometrical accuracy. Based on these results, abrasive blasting as a method to modify the tool surface and thus influencing the tribological behaviour was investigated. For the determination of the tribological mechanism of blasted tool surfaces, the influence of different blasting media as well as blasting pressures on the surface integrity and the friction were determined. Additionally, the functional stability of a modification was investigated. Finally, the correlations between surface properties and friction conditions were used to derive the mechanisms of blasted tool surfaces

Analysis of tribological behavior of surface modifications for a dry deep drawing process

The global trend towards more environment-friendly and sustainable production motivates the development of efficient manufacturing processes. Forming technology has great potential regarding that due to its high material efficiency. Research is necessary to improve the sustainability of established forming processes such as deep drawing. One possibility to improve the environmental friendliness of deep drawing is the realization of lubricant-free processes. This avoids the usage of harmful lubricants. Additionally, it has the potential to shorten process chains by eliminating cleaning steps. However, dry deep drawing is associated with challenges. Due to the lack of a lubricant between tool and workpiece, friction and wear increase. An approach to overcome these challenges is the usage of modified tool surfaces. In this context, the aim of this research is to investigate dry deep drawing operations under application-oriented conditions. Firstly, the cause-effect relationships between the properties and tribological performance for a-C:H and ta-C coating systems as well as laserbased micro-textures are investigated in strip drawing tests using the workpiece materials DC04 and AA5182. Therefore, different amorphous carbon coating approaches for DC04 and AA5182 are evaluated. Beside of coatings, diverse laser micro-texturings are investigated and applied on forming tools. Key parameters are identified, which result in low friction and adhesion. Based on these findings, the different modifications are evaluated. Promising modifications are selected and applied in a novel test rig under application-oriented conditions to analyze their durability. The test rig enables the time- and material-efficient forming of a great number of parts. In this regard, in addition to the occurring process forces, the tool and component topographies are determined at periodic intervals in order to derive the cause-effect relationships between friction, wear and component quality as well as to demonstrate the feasibility of dry deep drawing operations under application-oriented forming conditions.1324Bremen5

Measures for controlling the material flow when extruding sheet-bulk metal forming parts from coil

The increasing demand for lightweight design requires functional integration. This poses challenges to conventional manufacturing processes due to the rising geometrical complexity of components. The application of bulk forming operations to sheet metal, named sheet-bulk metal forming (SBMF), is one approach to overcome these challenges. Currently, mainly pre-cut blanks are applied in research of SBMF. Production from coil, in contrast, would combine the advantages of SBMF with the advantages of manufacturing from a coil regarding high output quantity. To research SBMF from coil, a lateral and a backward extrusion process are set up. In addition to a reduced geometrical accuracy of the parts, which is known from SBMF of pre-cut blanks, an anisotropic material flow is identified as a coil-specific challenge. The aim of this research is to investigate measures that extend the forming limits by means of a material flow control. For this purpose, a combined numerical-experimental approach is applied in order to analyze and evaluate an adaption of the width of the coil, the feed width, and the local friction as measures for material flow control. Particularly local adaptation of friction by means of modified tool surfaces reduces the anisotropic material flow and improves the geometrical accuracy of the parts

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Increasing demands in modern production pose new challenges to established forming processes. One approach to meet these challenges is the combined use of established process classes such as sheet and bulk forming. This innovative process class, also called sheet-bulk metal forming (SBMF), facilitates the forming of minute functional elements such as lock toothing and gear toothing on sheet-metal bodies. High tool loads and a complex material flow that is hard to control are characteristic of SBMF. Due to these challenging process conditions, the forming of functional elements is often insufficient and necessitates rework. This negatively affects economic efficiency. In order to make use of SBMF in industrial contexts, it is necessary to develop measures for improving the forming of functional elements and thereby push existing forming boundaries. This paper describes the design and numerical replication of both a forward and a lateral extrusion process so as to create involute gearing in combination with carrier teeth. In a combined numerical-experimental approach, measures for extending the die filling in sheet-metal extrusion processes are identified and investigated. Here, the focus is on approaches such as process parameters, component design and locally adjusted tribological conditions; so-called ‘tailored surfaces’. Based on the findings, fundamental mechanisms of action are identified, and measures are assessed with regard to their potential for application. The examined approaches show their potential for improving the forming of functional elements and, consequently, the improvement of geometrical accuracies in functional areas of the workpieces

Material flow control in sheet-bulk metal forming processes using blasted tool surfaces

Highly-integrated and closely-tolerated functional components can be produced by sheet-bulk metal forming which is the application of bulk forming operations on sheet metals. These processes are characterized by a successive and/or simultaneous occurrence of different load conditions such as stress and strain states which reduce the geometrical accuracy of the functional elements. Thus, one main challenge within sheet-bulk metal forming is the identification of methods to control the material flow and thus to improve the product quality. One suitable approach is to control the material flow by local modifications of the tribological conditions. Within this study requirements regarding the needed adaption of the tribological conditions for a specific sheet-bulk metal forming process were defined by numerical investigations. The results reveal that a local increase of the friction leads to an improved die filling of the functional elements. Based on these results abrasive blasting as a method to modify the tool surface and thus influencing the tribological behaviour was investigated. For the determination of the tribological mechanism of blasted tool surfaces, the influence of different blasting media as well as blasting pressures on the surface integrity and the friction were determined. The correlations between surface properties and friction conditions were used to derive the mechanisms of blasted tool surfaces

Methods for adhesion/friction reduction of novel wire-shaped actuators, based on shape memory alloys, for use in adaptive fiber-reinforced plastic composites

For fiber-reinforced plastic composites, fiber-matrix adhesion is a significant aspect of composite properties. While conventional lightweight structures are always aiming for high fiber-matrix adhesion, innovative and unconventional functional constructions require different concepts. The research work treating adaptive fiber-reinforced plastic composites with shape memory alloy wires presented here uses the approach of actuators freely movable within the composite. This is supposed to prevent mechanical tensions in the interfaces of actuator and composite structure, which would otherwise cause damages of the composite. This work examines hybrid yarns based on friction spinning technology, with shape memory alloy wires as their core component as well as glass fibers, and partly polypropylene, as their sheath component. Additionally, the surface properties of the shape memory alloy wires being used are modified by sanding and coating. The results of a characterization by pull-out testing clearly show that a coating of the shape memory alloy wires with an abherent causes considerable decrease in adhesion and friction in the interface and leads to the mobility of the shape memory alloy wires in the later composite. An even greater effect is attained by sheathing the hybrid yarns in an additional layer of polypropylene, compacting the yarn cross-section. Thus, the pull-out force could be reduced to 35–40% of the reference structure