Characterization of contact tensions during incremental forming of metal composites

Abstract

The realization of light weight design of components with local, load adapted properties is a major goal in the development of new manufacturing and processing methods of metal composite materials. A main challenge in the manufacturing of compounds by forming consists in the realization of the necessary conditions for the initiation of the diffusion process and the generation of metallic bonding. A combination of high contact tensions with specific forming conditions such as temperature distribution and surface enlargement is required in order to initiate the diffusion of atoms during the forming process. The article presents FEM-simulation and investigation of contact and forming conditions of aluminum-magnesium composites with respect to an incremental forming method. The characteristics of the compound materials, surface enlargement and local forming conditions as well as temperature gradients are important factors for the diffusion processes. The investigation of co ntact conditions during compound formation is a prerequisite for the further design of forming methods and the base for new approaches of generating composites of two light metal alloys into products with favorable properties such as high specific strength and corrosion resistance

A Rotary Compression Process for Producing Hollow Gear Shafts

“…At present, hollow stepped gear shafts are primarily produced by machining processes, which is connected with considerable material losses amounting up to 75% [ 6 ]. Nonetheless, metal forming methods are increasingly widely used to form solid semi-finished products that are then subjected to mechanical working in order to drill holes, remove machining allowance, or form teeth [ 7 , 8 , 9 ]. This way of manufacturing hollow parts ensures reduced material consumption (compared to machining methods) and higher strength properties (material fiber continuity is retained).…”

Experimental Studies and Finite Element Modeling on Incrementally Formed AZ61A Magnesium Alloy

“…Neugebauer et al [16] performed microstructural studies on incrementally formed magnesium -aluminium composite. It was found that a homogeneous interface was formed between under the given test condition.…”