Micro rotary swaging: process limitations and attempts to their extension

Kuhfuß, Bernd; Moumi, Eric; Piwek, Volker

doi:10.1007/s00542-008-0633-0

Cited by 25 publications

(14 citation statements)

References 2 publications

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“…During micro rotary swaging different limitations to the process occur [Kuh08a]. Furthermore, process parameters like the workpiece material, the die geometry, and the tribological conditions influence these limitations.…”

Section: Process Limitations and Measures For Their Extensionmentioning

confidence: 99%

Micro Forming Processes

Kuhfuß¹,

Schattmann

Jahn

et al. 2019

Lecture Notes in Production Engineering

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The projects of this chapter describe micro forming processes that are studied as single processes but can also be combined as process chains. Proven examples are material accumulation and succeeding rotary swaging, or rotary swaging and extrusion.Micro forming differs from macro forming due to scaling effects, which can mean both challenges and benefits. Problems may arise from the handling of fragile parts or adhesive forces between the micro parts or friction effects.Benefits from scaling effects are made use of in the project "Generation of functional parts of a component by laser-based free-form heading". The aim is a material accumulation that is generated from short duration laser melting. This material accumulation gives the basis for succeeding cold forming operations. The first powerful application for the new technology was upsetting. In the macro range, upset ratios of about 2.3 are achievable, but this is reduced in the micro scale due to earlier buckling of the components. In the micro scale, where cohesive forces can exceed the gravitational force, the molten material forms a droplet that remains adhered to the rod. Thus, upset ratios of up to 500 were reached. The process development was accompanied by a mathematical model and allows for a deep insight into the thermodynamics of laser-induced material accumulation in the micro range.The laser molten material accumulation could, for example, be further processed by micro rotary swaging. Though rotary swaging has been known in the macro range for a long time and is nowadays an intensively used process in the automotive industry to produce lightweight components from tubular blanks, there are only a few scientific works that have addressed material characteristics like the work hardening or residual stress that are linked to the process and machine parameters and the resulting material flow. Due to micro scale specifics that follow from the kinematics, i.e. relatively smaller stiffness against part buckling and wider tool gaps in the opened state, the feed rates achievable cannot compete with high throughput technologies that produce 500 parts per minute and more. One major aim of the project "Rotary swaging of micro parts" was to increase the productivity for the main process variants, namely infeed and plunge rotary swaging. This demanded also process modeling to understand how parameter variations like friction between tools and the work in the different zones of the swaging tools affect the process.From the modeling and simulation, separate process variations were deduced and investigated. For infeed swaging, a special workpiece clamping allows for compensation of the pushback force, which results in a 10-fold increase of the maximum feed rate. For plunge rotary swaging, an approach was tested to close the tools gaps during opening using elastic intermediate elements that encapsule the workpiece against the forming dies and enable a 4-fold increase of the radial feed rate. 28 B. Kuhfuss et al.Micro rotary swaging could become a base technology ...

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Section: Process Limitations and Measures For Their Extensionmentioning

confidence: 99%

Micro Forming Processes

Kuhfuß¹,

Schattmann

Jahn

et al. 2019

Lecture Notes in Production Engineering

Self Cite

View full text Add to dashboard Cite

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“…The workpieces are deformed in the swaging head by the forming tools (at least two segments), which rotate around the workpieces and perform radial oscillating movements at high frequency. There are two main variations of the process: plunge rotary swaging and infeed rotary swaging [Kuh08]. The diameter of the workpiece is reduced over the complete fed length during infeed rotary swaging, and it allows only local diameter reductions during plunge rotary swaging.…”

Section: Performance Of Micro Forming Toolsmentioning

confidence: 99%

Materials for Micro Forming

Zoch

Schulz

Cui

et al. 2019

Lecture Notes in Production Engineering

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In micro cold forming, the tools are loaded differently in various functional areas, and tailored material properties are therefore required. To meet this requirement, different tool steels can be applied in the specific regions of the tools, with a gradual material transition in between to ensure a good bonding. These kinds of composite material can be produced via two newly developed material manufacturing processes: co-spray forming and successive spray forming. The spray-formed materials have been hot formed to eliminate porosity and break up the carbide network. Moreover, a selective heat treatment based on middle frequency induction heating has been developed to simultaneously austenitize the tool steels at different temperatures since the different steels may require different heat treatment conditions. Finally, micro rotary swaging tools made of graded tool steels have been precisely machined in hardened condition due to the fine and homogeneous microstructure in the steels. The tools have been successfully applied to form wires of AISI 304 stainless steel.

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“…aluminium). This combination of materials and structures are predestinated for metal parts and assemblies in the micro scale, referring to first researches [9,10,11] within the Collaborative Research Centre (German Research Foundation) Micro Cold Forming -Processes, Characterisation, Optimisation ( Figure 8). …”

Section: Improvement Of Properties By Joint Structuresmentioning

confidence: 99%

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

et al. 2010

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In this article the production-orientated capabilities of light weight design to manufacture those components by rotary swaging are presented. Initially the principle and the important characteristics of the method are described. Afterwards hollow shaft components in the drive train of vehicles which can reduce the fuel consumption are explained by the stages of the process. Furthermore an approach to realise components in the micro scale is shown. Another focus on research projects is referred to the increase of productivity. Therefore experimental results with a high dynamic forging machine are discussed. New developments are using process synchronised feed kinematics to fulfil the required energy efficiency. Concluding arrangements to increase the energy efficiency for the infeed method in industrial use is demonstrated by a conceptual solution.

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Micro rotary swaging: process limitations and attempts to their extension

Cited by 25 publications

References 2 publications

Micro Forming Processes

Micro Forming Processes

Materials for Micro Forming

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

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