Investigation Of Tailored Blank Production By The Process Class Sheet-Bulk Metal Forming

Abstract

Low field permittivity of ferroelectric-ferrite ceramic composites: Experiment and modeling J. Appl. Phys. 112, 094103 (2012) Synthesis and efficient near-infrared quantum cutting of Pr3+/Yb3+ co-doped LiYF4 single crystals J. Appl. Phys. 112, 073518 (2012) Feasibility study in application of forging waste heat on absorption cooling system J. Renewable Sustainable Energy 4, 053109 (2012) Growth of (111) oriented NiFe2O4 polycrystalline thin films on Pt (111) via sol-gel processing J. Appl. Phys. 112, 063908 (2012) Large size metallic glass gratings by embossing J. Appl. Phys. 112, 064505 (2012) Additional information on AIP Conf. Proc. . In most cases the joining has a significant influence on the consecutively forming process due to varying local mechanical properties [3]. Hence the manufacturing of tailored blanks with a defined sheet thickness characteristic by the process class "sheet-bulk metal forming" is investigated. Subsequent the tailored blanks are provided for forming operations such as deep-drawing and the direct forming of complex functional shape elements. Aim of the project is the manufacturing of circular blanks with a sheet thickening in the exterior area by an upsetting operation. At the beginning, FE-based studies and physical experiments using blanks of DC04 are carried out, to create a fundamental knowledge base of the forming process. A comparatively large contact area between blank and forming tool, a threedimensional material flow and the low sheet thickness cause high process forces. Building up a multi-stage upsetting process with different sequenced tool geometries is one approach to meet this challenge. The material flow out of the sheet center is realized step-by-step to lower the actual contact area and sequential the appearing forces.

Flexibility in metal forming

“…The thickness of the rectangular ring portion equivalent to the bottom corner of the square cup was increased, particularly the thickening at the four corners of the rectangular ring undergoing large decrease in wall thickness in the deep drawing of square cups became double. Merklein and Opel [135] investigated the sheet-bulk metal forming process [130] to manufacture tailored blanks with a defined sheet thickness. Manufactured sheets with different thickness were employed in the deep-drawing process and forming process to obtain flexibility in geometric variation of sheet products.…”

Machines and Tools for Sheet-Bulk Metal Forming

“…The first one aims to manufacture tailored blanks with defined thickness distribution by rolling. This technology enables flexible tailored blank geometry in comparison to an upsetting process, which represents another possibility for the production of process adapted products by sheet-bulk metal forming [8]. The second concept is based on incremental forming and allows the production of asymmetric parts and a further processing of semi-finished parts as well.…”

Experimental investigation of the effect of specially manufactured blank (SMB) materials on deep drawing

“…1 Compared to products manufactured with the conventional method, tailored blanks provide a weight reduction potential of 20–34%. 2 In this regard, substituting equivalent tailor-welded blanks for monolithic blanks has proven to be a promising strategy for achieving the aforementioned goal and also for improving the crashworthiness of the vehicle structure. 1 These blanks are generally produced by welding two or more sheets of different thickness and with different mechanical properties.…”

“…Moreover, tailored blanks exhibit improved mechanical properties such as high strength and a homogenous grain structure; however, the achievable geometric design is restricted. 2 Specially manufactured blanks (SMBs) provide a better surface quality because they do not contain a weld seam and sudden thickness transitions. Because samples are precisely prepared by turning at the desired angle, the desired diameter is achieved and also, the cost of the blank is minimized.…”