Forming of Lightweight Metal Components: Need for New Technologies

Tekkaya, A. Erman; Khalifa, Nooman Ben; Grzancic, Goran; Hölker, Ramona

doi:10.1016/j.proeng.2014.09.125

Cited by 87 publications

(40 citation statements)

References 5 publications

(6 reference statements)

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“…Changed ecological and economic requirements as well as the demand for higher performing systems motivate lightweight construction [1]. Functional integration is one possibility to achieve lightweight systems [2]. This trend results in a more complex component geometry and thus higher demands regarding the production technology.…”

Section: Introductionmentioning

confidence: 99%

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Pilz¹,

Henneberg²,

Merklein³

2020

Manufacturing Rev.

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Increasing demands in modern production pose new challenges to established forming processes. One approach to meet these challenges is the combined use of established process classes such as sheet and bulk forming. This innovative process class, also called sheet-bulk metal forming (SBMF), facilitates the forming of minute functional elements such as lock toothing and gear toothing on sheet-metal bodies. High tool loads and a complex material flow that is hard to control are characteristic of SBMF. Due to these challenging process conditions, the forming of functional elements is often insufficient and necessitates rework. This negatively affects economic efficiency. In order to make use of SBMF in industrial contexts, it is necessary to develop measures for improving the forming of functional elements and thereby push existing forming boundaries. This paper describes the design and numerical replication of both a forward and a lateral extrusion process so as to create involute gearing in combination with carrier teeth. In a combined numerical-experimental approach, measures for extending the die filling in sheet-metal extrusion processes are identified and investigated. Here, the focus is on approaches such as process parameters, component design and locally adjusted tribological conditions; so-called 'tailored surfaces'. Based on the findings, fundamental mechanisms of action are identified, and measures are assessed with regard to their potential for application. The examined approaches show their potential for improving the forming of functional elements and, consequently, the improvement of geometrical accuracies in functional areas of the workpieces. This is an Open Access article distributed under the terms of the Creative Commons Attribution License (https://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

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Section: Introductionmentioning

confidence: 99%

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Pilz¹,

Henneberg²,

Merklein³

2020

Manufacturing Rev.

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show abstract

“…As important mechanical products, gears, spline shafts, and other transmission parts are widely used in various mechanical products [1,2], the rapid development of major industries, such as automobile, aircraft, special engineering machinery, and wind and nuclear power equipment, has led to a huge demand for transmission parts with higher performance [3,4]. In the production of mechanical parts, objectives such as creating a lightweight design, establishing short process chains, and improving material and energy efficiency are difficult to meet using the current cutting methods to shape the external teeth of transmission parts [3,5,6].…”

Section: Introductionmentioning

confidence: 99%

Process Parameters Decision to Optimization of Cold Rolling-Beating Forming Process through Experiment and Modelling

Yang

et al. 2019

Metals

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The cold roll-beating forming (CRBF) process is a particular cold plastic bulk forming technology for metals that is adequate for shaping the external teeth of important parts. The process parameters of the CRBF process were studied in this work to improve the process performance. Of the CRBF process characteristics, the forming forces, tooth profile angle, surface roughness, and forming efficiency were selected as the target indices to describe the process performance. Single tooth experimental tests of ASTM 1045 steel were conducted with different roll-beating modes, spindle rotation speeds, and feed speeds. Using analysis of variance (ANOVA) and regression analysis, the influence of the process parameters in each index was investigated, and regression models of each index were established. Then, the linear weighted sum method and compound entropy weight method were used to determine the process parameters for multi-objective optimization. The results show that the impact capacity and optimum value range of the process parameters vary in different indices, and that, to achieve the comprehensive optimum effect of a small forming force, high product quality, and high forming efficiency, the optimal process parameter combination is the up-beating mode, a spindle rotation speed of 801 r/min, and a feed speed of 960 mm/min.

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“…Aluminum extruded profile is frequently used in aerospace applications due to their advantages of low density, high stiffness, excellent corrosion resistance and easy to recycle [1][2][3].The use of aluminum material can meet the requirements of aerospace industry for lightweight and high-performance, i.e., improving the carrying capacity of aerocraft, increasing the cruise range and reducing fuel consumption. Currently, aluminum alloys are the main material component of subsonic aircraft, and also occupy a certain proportion of application on supersonic aircraft.…”

Section: Introductionmentioning

confidence: 99%

Electrically Assisted Stretch Bending of Aluminum Extruded Profile

Cao¹,

Zeng²,

Liu³

2018

MATEC Web Conf.

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Abstract. Aluminum extruded profile is widely applied in aircraft frame parts whose forming quality is directly related to the assembly accuracy, aerodynamic shape and the service life of aircraft. However, it normally faces difficulties of large springback and low forming limit while forming at room temperature by stretch bending method. Here, electricity was applied in stretch bending process to heat aluminum profile aiming at improving the formability and reducing the springback by using electrically assisted stretch bending machine which is consisted of electrical power with the capability of 10000A and 40000kN stretching force for each hydraulic cylinder. In this research, a set of uniaxial tension tests was performed at different temperature to determine the relationship between the deformation behavior of aluminum profile and temperature. Then, a series of stretch bending tests were conducted to investigate the springback law of the aluminum profile. The corresponding stretch bending parts were obtained under different conditions. The experiment results show that, the plasticity of aluminum profile can be improved when the temperature rises, and the springback of aluminum profile can be reduced even more due to the electrical heating effect compared to the cold stretch bending process. Therefore, the forming accuracy of aluminum profile can be improved in electrically assisted stretch bending process.

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Forming of Lightweight Metal Components: Need for New Technologies

Cited by 87 publications

References 5 publications

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Process Parameters Decision to Optimization of Cold Rolling-Beating Forming Process through Experiment and Modelling

Electrically Assisted Stretch Bending of Aluminum Extruded Profile

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