Abstract
Hollow or tubular preforms are used to meet lightweight requirements and reduce production costs of cold formed components. In order to increase efficiency of manufacturing, a combined forming process was developed, which will be presented in this paper: manufacturing of hollow preforms by combining processes backward cup extrusion and piercing. With regard to combined forming processes in the field of cold forging, disclosed work consists of numerical identification of significant process input variables, process outcomes, and the process limits.
Highlights
Cold forged components can contribute essentially to diverse lightweight strategies when it comes to increasing the efficiency of manufacturing processes with regard to the use of material
The use of material can be reduced using the occurring cold work hardening and the process-specific possibility of creating a continuous grain structure, which is designed for specific loads
A reduction of material use of cold forged components while maintaining the functional demands is realized by using hollow designs
Summary
Cold forged components can contribute essentially to diverse lightweight strategies when it comes to increasing the efficiency of manufacturing processes with regard to the use of material. Conducted investigation includes the influence of different punch geometries (e.g. figure 3), forming temperatures, tool and workpiece materials as well as the use of weight on the target parameter’s hardness, microstructure, wear behavior, compliance with the shape and dimensional tolerances of the hole produced, and the surface quality. The investigations of [12, 14, 13, 11, 10] with regard to combined precision forging and piercing show that little or only very few analogies exist between the punching of forged parts and the piercing of cold extruded parts This becomes apparent for example in [10], where it is stated that the surface quality of the fracture surface of the hole is higher than the surface quality of the part produced when forming the holes.
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