Investigation on micro-textured tappets from design and production to the application properties

Abstract

In industrial sectors like medical and automotive engineering, the demand for metal components with a high function integration brings conventional production technologies to their limits. This motivates research on innovative processes, which can meet the present requirements on fabricated parts and consequently also the demands on the applied manufacturing process. Part-sided, a high strength, narrow dimensional tolerances and a large functionality is often desired. In addition, an economical component production calls for processes with high material utilization as well as the achievement of short cycle times. The process class of sheet-bulk metal forming, characterized by the application of bulk forming operations on sheet metal, offers the potential to meet these requirements. Currently, sheet-bulk metal forming is mainly used for the fabrication of components with functional elements of macroscopic size. However, microscopic elements and micro-textured surfaces are of high interest for applications in prosthetics and automotive engineering. The objective of this study is therefore to develop an application-oriented method for the design, production and testing of 16MnCr5 metal components, manufactured by a combined process of sheet-bulk metal forming, creating a defined microstructure on the surface. Since the selection of a suitable texture layout and geometry is crucial for tribological optimization, these are designed for their application using numerical elastohydrodynamic lubricant simulations. The contact conditions occurring in the application are modelled as realistically as possible so that texture designs suitable for production can subsequently be compared in test bench trials. It is shown that the tappets produced by forming technology can be efficiently investigated with the test rig presented.