Abstract
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.
Highlights
The increasing demand for lightweight construction, for example in transportation engineering [1], confronts production technology with the challenge to reduce the system weight
In addition to a reduced geometrical accuracy of the parts, which is known from sheet-bulk metal forming (SBMF) of pre-cut blanks, an anisotropic material flow is identified as a coil-specific challenge
The objective of the presented research is to create a fundamental understanding of measures for improving the geometrical accuracy of components produced by SBMFprocesses from coil by means of a material flow control
Summary
The increasing demand for lightweight construction, for example in transportation engineering [1], confronts production technology with the challenge to reduce the system weight. One approach to meet this challenge is component design with functional integration [2] This approach achieves the aim of lightweight construction by reducing the weight of the system [2]. Due to the resulting increase in geometrical complexity of the components, conventional forming processes reach their limits [3]. This motivates research of the process class of sheet-bulk metal forming (SBMF). Stimulated by the importance of SBMF for the manufacturing of functionally integrated components, the process class is subject of numerous investigations. The results regarding the measures are synthesized as well as evaluated, and recommendations for a material flow control in SBMF of parts from coil are concluded
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