2D-simulation of Material Flow During Infeed Rotary Swaging Using Finite Element Method

Moumi, Eric; Ishkina, Svetlana; Kuhfuß, Bernd; Hochrainer, Thomas; Struss, Adrian; Hunkel, M.

doi:10.1016/j.proeng.2014.10.331

Cited by 34 publications

(34 citation statements)

References 10 publications

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“…These studies lead to the formulation of the neutral plane (NP), where no axial flow of the material can be detected. 19 The material left or right of the NP flows in the backward or forward direction. Thus, the location of the NP represents the productivity, due to the fact that more or less material flows into the reduction zone dependent on the friction between the tools and the work piece.…”

Section: Process Modeling and Simulationmentioning

confidence: 99%

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Dry rotary swaging–approaches for lubricant free process design

Böhmermann

Hasselbruch

Herrmann

et al. 2015

Int. J. of Precis. Eng. and Manuf.-Green Tech.

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Section: Process Modeling and Simulationmentioning

confidence: 99%

“…Commonly twodimensional axisymmetric simulations are performed for radial forging and rotary swaging. [17][18][19] The model for the rotary swaging is implemented with the software Simulia ABAQUS 6.13-1 and consists of two parts, tool and work piece (see Fig. 8).…”

Section: Process Modeling and Simulationmentioning

confidence: 99%

Dry rotary swaging–approaches for lubricant free process design

Böhmermann

Hasselbruch

Herrmann

et al. 2015

Int. J. of Precis. Eng. and Manuf.-Green Tech.

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“…In recent years rotary swaging has been studied using finite element method (FEM) to examine strain and stress distributions [2,3] and the material flow by visualization of the neutral plane [4]. In the forming process the neutral plane (NP) represents the plane in which the material features no flow in axial direction.…”

Section: Introductionmentioning

confidence: 99%

“…The material before or behind the NP flows against or in feeding direction. The productivity increases with the distance between neutral plane and calibration zone [4]. The investigations are conducted with regard to the influence of axial feed velocity [5] or friction and tool angle [6].…”

Section: Introductionmentioning

confidence: 99%

“…In case of dry rotary swaging the needed process forces are changing. The distance of the neutral plane Z NP is reduced which can lead to a non-economical process [4,8]. The approach to cope with this challenge is to control the material flow and thus the required forces by a combination of coating and structuring of the reduction zone of the tools.…”

Section: Introductionmentioning

confidence: 99%

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FEM simulation of infeed rotary swaging with structured tools

Herrmann

Schenck

Kuhfuß

2015

MATEC Web of Conferences

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Abstract.Rotary swaging is an incremental cold forming process for rods and tubes. Infeed rotary swaging with structure in the reduction zone of the tools is investigated using a two dimensional finite element simulation. A few geometrical parameters are varied, for cosine and skew stairway shapes. The effective tool angle is kept constant. The influence is evaluated by the radial and axial process forces. Furthermore, the material flow is visualized by the neutral plane. The simulation results are quantitatively compared to each other to analyse the reaction force F A , which acts against the feeding force. Also, the results serve to find suitable geometries to be transferred to rotary swaging tools for practical application. It is shown that the shapes have a significant effect on the forces and the location of the neutral plane. Finally a first swaging tool is modified with an exemplary geometry for experimental investigations.

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Micro Forming Processes

Kuhfuß¹,

Schattmann

Jahn

et al. 2019

Lecture Notes in Production Engineering

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The projects of this chapter describe micro forming processes that are studied as single processes but can also be combined as process chains. Proven examples are material accumulation and succeeding rotary swaging, or rotary swaging and extrusion.Micro forming differs from macro forming due to scaling effects, which can mean both challenges and benefits. Problems may arise from the handling of fragile parts or adhesive forces between the micro parts or friction effects.Benefits from scaling effects are made use of in the project "Generation of functional parts of a component by laser-based free-form heading". The aim is a material accumulation that is generated from short duration laser melting. This material accumulation gives the basis for succeeding cold forming operations. The first powerful application for the new technology was upsetting. In the macro range, upset ratios of about 2.3 are achievable, but this is reduced in the micro scale due to earlier buckling of the components. In the micro scale, where cohesive forces can exceed the gravitational force, the molten material forms a droplet that remains adhered to the rod. Thus, upset ratios of up to 500 were reached. The process development was accompanied by a mathematical model and allows for a deep insight into the thermodynamics of laser-induced material accumulation in the micro range.The laser molten material accumulation could, for example, be further processed by micro rotary swaging. Though rotary swaging has been known in the macro range for a long time and is nowadays an intensively used process in the automotive industry to produce lightweight components from tubular blanks, there are only a few scientific works that have addressed material characteristics like the work hardening or residual stress that are linked to the process and machine parameters and the resulting material flow. Due to micro scale specifics that follow from the kinematics, i.e. relatively smaller stiffness against part buckling and wider tool gaps in the opened state, the feed rates achievable cannot compete with high throughput technologies that produce 500 parts per minute and more. One major aim of the project "Rotary swaging of micro parts" was to increase the productivity for the main process variants, namely infeed and plunge rotary swaging. This demanded also process modeling to understand how parameter variations like friction between tools and the work in the different zones of the swaging tools affect the process.From the modeling and simulation, separate process variations were deduced and investigated. For infeed swaging, a special workpiece clamping allows for compensation of the pushback force, which results in a 10-fold increase of the maximum feed rate. For plunge rotary swaging, an approach was tested to close the tools gaps during opening using elastic intermediate elements that encapsule the workpiece against the forming dies and enable a 4-fold increase of the radial feed rate. 28 B. Kuhfuss et al.Micro rotary swaging could become a base technology ...

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2D-simulation of Material Flow During Infeed Rotary Swaging Using Finite Element Method

Cited by 34 publications

References 10 publications

Dry rotary swaging–approaches for lubricant free process design

Dry rotary swaging–approaches for lubricant free process design

FEM simulation of infeed rotary swaging with structured tools

Micro Forming Processes

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