Abstract
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.
Highlights
A newly developed class of forming processes called sheet-bulk metal forming (SBMF) combines the advantages of bulk forming operations on sheet metal workpieces [1]
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
This led to an increase in roughness in the material flow direction and to an increase in process forces compared to the HF1 structure, as can be seen in particular in the tests with the DC04 material
Summary
A newly developed class of forming processes called sheet-bulk metal forming (SBMF) combines the advantages of bulk forming operations on sheet metal workpieces [1]. Kirchner et al attributed the reduction of the mean stress during superimposed oscillation forming to the elastic relaxation of the samples during stress release [8] Another approach explains the forming force reduction with surface-related effects. To extend the process limits of the new technology SBMF and to create an application-related investigation environment, a multistage SBMF process, in which a component with an external and an internal gearing is produced in the three process steps from a sheet metal ronde, was developed [10] 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]
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