Light weight design of rotary swaged components and optimization of the swaging process

Piwek, Volker; Kuhfuß, Bernd; Moumi, Eric; Hork, Martin

doi:10.1007/s12289-010-0902-1

Cited by 27 publications

(11 citation statements)

References 4 publications

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“…This production technique provides several advantages such as high static and dynamic strength due to strain hardening [2]. Additionally, by the use of hollow shafts and by the advantageous development of the wall thickness during rotary swaging, cost-effective production of lightweight components is possible due to the optimal use of material resources [3].…”

Section: Introductionmentioning

confidence: 99%

Influence of Process Fluctuations on Residual Stress Evolution in Rotary Swaging of Steel Tubes

et al. 2019

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Infeed rotary swaging is a cold forming production technique to reduce the diameter of axisymmetric components. The forming is achieved discontinuously by a series of radial strokes that are spread over the shell of the part. Due to tolerances within the rotary swaging machine, these strokes perform individually and the resulting stroke pattern is not homogeneous with regards to circumferential and longitudinal distribution. Nevertheless, in combination with the high number of performed strokes and the large contact area between the dies and the part, the external part properties, such as diameter, roundness and surface roughness, show even values along the finished part. In contrast, strength-defining internal part properties, like microstructure and residual stress components, are more sensitive to the actual pattern and temporal sequence of the individual strokes, which is investigated in this study. The impact of process fluctuations during the conventional process, which are induced by the tolerances of machine tool components, was verified by numerical simulations, physical tests and measurements of residual stress distributions at the surface and at depth. Furthermore, a method is introduced to maintain the stroke following angle ∆φ at zero by flat dies, and thus the actual pattern and temporal sequence of the strokes was homogenized. The results show that the residual stress fluctuations at the surface could be controlled and reduced. Furthermore, it is demonstrated that the depth profile of the residual stresses at a distance of 300 µm from the surface developed independently from the process fluctuations.

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Section: Introductionmentioning

confidence: 99%

Influence of Process Fluctuations on Residual Stress Evolution in Rotary Swaging of Steel Tubes

et al. 2019

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“…It may be advisable to use suitable auxiliary structures, such as those suggested by Hong and Hoffmann, when installing the specimens [4]. The testing of round specimens, on the other hand, poses a greater challenge, as is the case, for example, with the cold forming process of rotary swaging, the principle of which is explained for example by Kuhfuss et al or Piwek et al [5,6]. In this process, a wire shaped semi-finished product with a diameter of 1 mm is rotary swaged to, for example, a diameter of 0.5 mm and cold worked at the same time.…”

Section: Clamping Devicesmentioning

confidence: 99%

Development and application of methods to characterize micro semi-finished products and micro components

2018

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In the production of semi-finished products for the production of microcomponents and the components themselves, the characterization of their physical properties is of particular importance. Due to the often oligocrystalline character of these semi-finished products and components, it is necessary to use a suitable testing technique for static and dynamic investigations, as the mechanical properties are not transferable from the macroscopic point of view. In addition, the micro semi-finished products and components often show inhomogeneities induced by the manufacturing process. On the one hand, these are directly reflected in the microstructure and on the other hand they have an effect on quantities such as hardness or residual stresses, which play a decisive role in the application. Mechanical testing, conventional metallography, scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), ultra-microhardness testing and X-ray residual stress analysis were used as measuring and analysis techniques suitable for the sub-millimeter range. In the following, the possibilities and limitations of two these methods are illustrated using the example of mechanical testing and EBSD. In this paper several examples for possible characterization techniques are given.

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“…The results presented that a swaged shell nose part with a higher reliability could be successfully produced by rotary swaging. Piwek et al 13 presented the production-orientated capabilities of light-weight design to manufacture those components by rotary swaging. As observed from the above studies, none of them optimize rotary swaging parameters systematically in order for a better forging quality to be obtained.…”

Section: Introductionmentioning

confidence: 99%

Mechanical properties optimization of the steering column based on multi-objective optimization design

Chen

Wang

Lv³

2016

Advances in Mechanical Engineering

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The mechanical properties of the steering column have a significant influence on the comfort and stability of a vehicle. In order for the mechanical properties to be improved, the rotary swaging process of the steering column is studied in this article. The process parameters, including axial feed rate, hammerhead speed, and hammerhead radial reduction, are systematically analyzed and optimized based on a multi-objective optimization design. The response surface methodology and the genetic algorithm are employed for optimal process parameters to be obtained. The maximum damage value, the maximum forming load, and the equivalent strain difference obtained with the optimal process parameters are, respectively, decreased by 30.09%, 7.44%, and 57.29% compared to the initial results. The comparative results present that the quality of the steering column is improved. The torque experiments and fatigue experiments are conducted with the optimal steering column. The maximum torque is measured to be 260 NM, and the service life is measured to be 2 weeks (40 NM, 2500 times), which are, respectively, increased by 8.3% and 8.69% compared to the initial results. The above results display that the mechanical properties of the steering column are optimized to verify the feasibility of the multi-objective optimization method.

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Light weight design of rotary swaged components and optimization of the swaging process

Cited by 27 publications

References 4 publications

Influence of Process Fluctuations on Residual Stress Evolution in Rotary Swaging of Steel Tubes

Influence of Process Fluctuations on Residual Stress Evolution in Rotary Swaging of Steel Tubes

Development and application of methods to characterize micro semi-finished products and micro components

Mechanical properties optimization of the steering column based on multi-objective optimization design

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