Abstract
Due to rising demands regarding the functionality and load-bearing capacity of functional components such as synchronizer rings in gear systems, conventional forming operations are reaching their limits with respect to formability and efficiency. One way to meet these challenges is the application of the innovative process class of sheet-bulk metal forming (SBMF). By applying bulk forming operations to sheet metal, the advantages of both process classes can be combined, thus realizing an optimized part weight and an adapted load-bearing capacity. Different approaches to manufacturing relevant part geometries were presented and evaluated regarding the process properties and applicability. In this contribution, a self-learning engineering workbench was used to provide geometry-based data regarding a novel component geometry with circumferential involute gearing manufactured in an SBMF process combination of deep drawing and upsetting. Within the comprehensive investigations, the mechanical and geometrical properties of the part were analyzed. Moreover, the manufactured components were compared regarding the increased fatigue strength in cyclic load tests. With the gained experimental and numerical data, the workbench was used for the first time to generate the desired component as a CAD model, as well as to derive design guidelines referring to the investigated properties and fatigue behavior.
Highlights
Usingaa conventional conventionalblank blankmade madeout outofofthe themild milddeep deepdrawing drawingsteel steelDC04, DC04,the thematerial materialvolume volume provided in the area of the later cup wall was not sufficient to allow a proper filling of the provided in the area of the later cup wall was not sufficient to allow a proper filling of cavity, only reaching a maximum of process failures such as the cavity, only reaching a maximum of 86%
An increasing duehardening to cold hardening during the operation represented another limiting for realizing desiredthe geometry, reaching forming operation represented anotherfactor limiting factor forthe realizing desired geometry, reaching an average of 233.4 ± 30.1 HV0.05, showing an increase of 87% compared to the initial hardness and revealing an inhomogeneous distribution across the cup wall, referring to the high standard deviation
A fundamental analysis of the mechanical properties of components manufactured by sheet-bulk metal forming processes was carried out
Summary
In the manufacturing industry, the development of innovative solutions is essential to meet requirements and emerging challenges. New approaches such as light-weight design and functional integration are applied to reduce weight on the one hand, and to increase the functionality on the other hand [2]. The innovative process class of sheetbulk metal forming (SBMF) offers the possibility to meet these challenges by an efficient manufacturing of functional components with a shortened process chain and improved mechanical properties [3]. The conflict between the desired geometry and the process limits could be shown and the necessity of pre-calculated values referring to the mechanical properties and the performance in operation for an optimized component design could be demonstrated. Since the functional components are exposed to cyclic load during usage [5], the analysis and evaluation of the fatigue life is mandatory for characterizing the potential of an increased performance
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