Dry Rotary Swaging with Structured Tools

Herrmann, Marius; Schenck, Christian; Kuhfuß, Bernd

doi:10.1016/j.procir.2016.01.150

Cited by 23 publications

(9 citation statements)

References 8 publications

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“…The general experimental procedure comprising of the actual dry rotary swaging as well as the methodology of abrasive particle collection and analysis was introduced before in [8]. This procedure is adopted for the presented work, but for the sake of completeness will hereinafter again be explained in detail.…”

Section: Methodsmentioning

confidence: 99%

“…Forming dies exhibiting sine wave structures (amplitude A = 0.05 mm, wavelength λ = 1.3 mm) were applied to the machining of tubes from 1.0038 construction steel. In comparison to unstructured rotary swaging dies, the dies' design reduced the tracking error of the feed system associated with the axial reaction force F A by 50 % for dry machining and up to 400 % when machining under lubricated conditions [8]. Furthermore, such structured forming dies with additional tungsten doped amorphous diamond like carbon coating (a-C:H:W) plus a-C:H top layer were tested against steel tubes.…”

Section: Introductionmentioning

confidence: 99%

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Reducing Abrasive Particle Generation in Dry Rotary Swaging by Utilizing DLC Hard Coated Dies

et al. 2018

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The emphasis of this paper is the investigation of the impact of the diamond like carbon (DLC) hard coating system on the amount of abrasive particles being generated during dry rotary swaging. Rotary swaging experiments applying coated and uncoated macro structured forming dies were carried out against aluminum and steel work pieces varying the process parameter feed velocity. It was found that DLC coatings effectively reduce the generation of abrasive particles from the work piece. For dry machining of aluminum the amount was reduced to a tenth of the original quantity achieved with uncoated dies. The results are discussed with regard to the mechanics of interfacing surfaces. Additionally, forming dies exhibiting macro structures surfaces of improved design were introduced and applied in dry rotary swaging experiments, which allowed minimizing the abrasive particle generation.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Reducing Abrasive Particle Generation in Dry Rotary Swaging by Utilizing DLC Hard Coated Dies

et al. 2018

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“…[103,159] Rotary swaging is a metal forming process for changing diameter of a tubular or solid bar. Most applications involve the reduction [65]. Axial-Radial-Forming was developed in order to manufacture additional shapes like shaft collar in gear shafts which requires a local increase of diameter.…”

Section: Incremental Bulk Forming By Discrete Cogging Operationmentioning

confidence: 99%

Flexibility in metal forming

et al. 2018

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Flexibility in metal forming is needed more than ever before due to rapidly changing customer demands. It paves the way for a better control of uncertainties in development and application of metal forming processes. Although flexibility has been pursued from various viewpoints in terms of machines, material, process, working environment and properties, etc., a thorough study of the concept was undertaken in order to with problems of manufacturing competiveness and tackle new challenges of manufacturing surroundings. Therefore, in this paper, flexibility in forming is reviewed from the viewpoints of process, material, manufacturing environment, new process combinations and machine-systemsoftware interactions.

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“…For each s0 three workpieces were prepared. Conventional swaging dies with tungsten carbide layer in the reduction zone were used [5], the contact pair was lubricated with oil (Condocut KNR 22). During the process the workpieces were fed into the center of the dies with a length of 70 mm.…”

Section: Rnp = 100% * (D1/2 -Rnr) / S1mentioning

confidence: 99%

“…Thus, the same amount of material is deformed with the same conditions with every further stroke. In this situation, a stable phase is assumed [5]. In former research, rotary swaging has been widely investigated by Finite Element Method (FEM) and experiments.…”

Section: Introductionmentioning

confidence: 99%

Axial and Radial Material Flow Analysis in Infeed Rotary Swaging of Tubes

et al. 2018

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In rotary swaging – an incremental cold forming production technique to reduce the diameter of axisymmetric parts – the material flow can be assumed to be predominantly axial and radial. The actual ratio of this axial and radial flow influences the mechanical properties and especially in tube forming the final geometry. It is known that during mandrel free infeed rotary swaging of tubes the wall thickness changes. The change is depending on the process parameters like incremental and cumulated strain. Hence, the ratio of axial and radial material flow changes. Consequently, the analysis of the wall thickness of rotary swaged tubes enables fundamental insight how to control the material flow direction. In this study, the infeed rotary swaging process of steel tubes with different wall thicknesses from 3 mm to 7 mm and rods were investigated with FEM under two feeding velocities. The axial and radial material flow and the resulting geometry were studied by the relative wall thickness. It could be seen that the relative wall thickness was affected by the feeding velocity as well as the initial wall thickness. The findings of the simulation were validated by rotary swaging experiments.

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Dry Rotary Swaging with Structured Tools

Cited by 23 publications

References 8 publications

Reducing Abrasive Particle Generation in Dry Rotary Swaging by Utilizing DLC Hard Coated Dies

Reducing Abrasive Particle Generation in Dry Rotary Swaging by Utilizing DLC Hard Coated Dies

Flexibility in metal forming

Axial and Radial Material Flow Analysis in Infeed Rotary Swaging of Tubes

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