Abstract
A new sheet-bulk metal forming process for the production of bulk components out of a flat sheet has been developed. Superimposed oscillation has been applied to the new process. By this means, process limits regarding better mould filling were expanded, and forming forces could be reduced. In order to investigate the effects of superimposed oscillation on material behaviour, plane strain and ring compression tests were carried out. The superimposed oscillated plane strain compression test showed a reduction in biaxial flow stress and thus in plastic work. Furthermore, reduced friction and roughness were verified in ring compression tests using superimposed oscillation.
Highlights
Nowadays, resource efficiency in the form of strict emission standards, lightweight design, and simultaneous cost reduction is very important in metal forming
In order to investigate the influence of superimposed oscillation, the microstructure of the material was characterised under a Transmission electron microscopy (TEM) microscope after a tensile test
This study is focused on the development of a new sheet-bulk metal forming (SBMF) process as well as on the expansion of its process limitsisby superimposed oscillation. of
Summary
Resource efficiency in the form of strict emission standards, lightweight design, and simultaneous cost reduction is very important in metal forming. The SBMF technology enables the production of symmetric and asymmetric solid metal parts out of a flat sheet with functional components. This new technology has enormous potential to shorten the process chain and reduce manufacturing costs. The influence of superimposed oscillation in the ultrasonic range on metal forming processes can be assessed in two effects. By means of the design of this hydraulic system consisting of a rotary piston valve and a high-frequency cylinder, high excitation amplitudes can be realised at a high excitation frequency The integration of this oscillation in the SBMF process to overcome forming limits is a subject of this study.
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