Experimental and numerical analysis of tribological effective surfaces for forming tools in Sheet-Bulk Metal Forming

Kersting, Petra; Gröbel, Daniel; Merklein, Marion; Sieczkarek, Peter; Wernicke, Sebastian; Tekkaya, A. Erman; Krebs, Eugen; Freiburg, Dennis; Biermann, Dirk; Weikert, Tim; Tremmel, Stephan; Stangier, Dominic; Tillmann, Wolfgang; Matthias, Steffen; Reithmeier, Eduard; Löffler, Maria; Beyer, Florian; Willner, Kai

doi:10.1007/s11740-015-0651-6

Cited by 28 publications

(7 citation statements)

References 17 publications

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“…needed to be generated, since these surface modifications proved to be promising in, e forging processes for controlling the material flow [20]. The functionality and applicabi of these modified surfaces is strongly dependent on the machining process-related pr erties in terms of topography design, residual stress state and fatigue behavior.…”

Section: Methodsmentioning

confidence: 99%

Analysis of the Influence of Surface Modifications on the Fatigue Behavior of Hot Work Tool Steel Components

Wild¹,

Platt

Biermann

et al. 2021

Materials

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Hot work tool steels (HWS) are widely used for high performance components as dies and molds in hot forging processes, where extreme process-related mechanical and thermal loads limit tool life. With the functionalizing and modification of tool surfaces with tailored surfaces, a promising approach is given to provide material flow control resulting in the efficient die filling of cavities while reducing the process forces. In terms of fatigue properties, the influence of surface modifications on surface integrity is insufficiently studied. Therefore, the potential of the machining processes of high-feed milling, micromilling and grinding with regard to the implications on the fatigue strength of components made of HWS (AISI H11) hardened to 50 ± 1 HRC was investigated. For this purpose, the machined surfaces were characterized in terms of surface topography and residual stress state to determine the surface integrity. In order to analyze the resulting fatigue behavior as a result of the machining processes, a rotating bending test was performed. The fracture surfaces were investigated using fractographic analysis to define the initiation area and to identify the source of failure. The investigations showed a significant influence of the machining-induced surface integrity and, in particular, the induced residual stress state on the fatigue properties of components made of HWS.

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Section: Methodsmentioning

confidence: 99%

Analysis of the Influence of Surface Modifications on the Fatigue Behavior of Hot Work Tool Steel Components

Wild¹,

Platt

Biermann

et al. 2021

Materials

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“…This disparate process behavior was attributed to the varying topography of both surface structures. Based on the results and further investigations, it can be assumed that the material flow along the crests of the structure HF 1 is enhanced [15,19]. The structure HF 1 was applied on the active parts of the tools, leading to an improved material flow out of the compression zone.…”

Section: Plane-strain Compression Testsmentioning

confidence: 99%

“…It has already been shown that functional surface structures as well as additional coating systems can improve the mold filling of filigree secondary form elements by adjusting the tribological contact conditions between tool and workpiece [13,14]. By specifically modifying the contact conditions with the use of tailored surfaces, the material flow in forming processes can be adjusted to enhance the molding [12,15,16]. Furthermore, the application of additional coating systems can have a positive effect not only on friction but also on the wear behavior of the mold [14,17,18].…”

Section: Introductionmentioning

confidence: 99%

Influence of Tailored Surfaces and Superimposed-Oscillation on Sheet-Bulk Metal Forming Operations

Behrens

Tillmann

Biermann

et al. 2020

JMMP

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Producing complex sheet metal components in fewer process steps motivated the development of the innovative forming process called sheet-bulk metal forming (SBMF). In this process, sheet metal forming and bulk-metal forming are combined to create a unique forming process in which a component with external and internal gearing is produced in three production steps. However, the high degrees of deformation that occur using high-strength steels and the number of different process steps result in high process forces, strongly limiting the service life of tools. To reduce the forming force during SBMF processes, tool and process modifications were investigated. Therefore, plane-strain compression tests were conducted to examine the influence of a CrAlN PVD coating and tailored surfaces produced by high-feed milling (HF) of tool-active elements on the material flow of the specimens. In addition to the tool-sided modifications, the influence of an oscillation overlay during the forming process was investigated. Based on the results of the compression tests, the surfaces of the active tool elements of the SBMF process were modified in order to transfer the basic experimental results to the production of a functional component. The friction is thus adapted locally in the SBMF process.

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“…Contact with friction along the surface of these objects was modelled by means of the Coulomb friction law (μ = 0.15) [12].…”

Section: Finite Element Modellingmentioning

confidence: 99%

Incipient and repeatable plastic flow in incremental sheet-bulk forming of gears

Sieczkarek

Wernicke

Gies

et al. 2016

Int J Adv Manuf Technol

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This paper analyses the differences between incipient and repeatable material flow in the incremental sheet-bulk metal forming (SBMF) of gears produced by indentation along the direction perpendicular to the sheet thickness. The underfilling of the punch cavity during the first indentation, which prevents the production of sound disk gears, is explained on the basis of constrained material flow under material strain hardening. A solution based on the utilization of a tailored disk blank is proposed to overcome this defect. The geometry of the tailored disk blank is determined by means of finite element analysis, and the overall methodology involved material characterization and experimentation with DC04 mild steel. The discussion on the extent of the plastic deformation region under constrained and free-material flow during indentation is complemented by experimental results obtained with a flat punch in rectangular sheet blanks of aluminium EN AW-1050A.

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Experimental and numerical analysis of tribological effective surfaces for forming tools in Sheet-Bulk Metal Forming

Cited by 28 publications

References 17 publications

Analysis of the Influence of Surface Modifications on the Fatigue Behavior of Hot Work Tool Steel Components

Analysis of the Influence of Surface Modifications on the Fatigue Behavior of Hot Work Tool Steel Components

Influence of Tailored Surfaces and Superimposed-Oscillation on Sheet-Bulk Metal Forming Operations

Incipient and repeatable plastic flow in incremental sheet-bulk forming of gears

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