Orbital Forming of Tailored Blanks for Industrial Application

Hetzel, Andreas; Lechner, Michael

doi:10.1007/978-3-030-61902-2_20

Cited by 3 publications

(8 citation statements)

References 13 publications

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“…The process parameters were defined in accordance with previous investigations on orbital forming of DC04 [8]. To obtain a sufficient material thickening in the outer area, a forming force of F = 3,000 kN was selected.…”

Section: Or Orbital F Bital Forming Ormingmentioning

confidence: 99%

“…Another promising method to increase die filling is the application of semi-finished products with an adjusted thickness profile. These tailored blanks provide material in the area where it is especially required [7] and can increase the material efficiency by processing a thinner initial blank [8]. Furthermore, the targeted adaption of mechanical properties are to be considered beneficial [8].…”

Section: Intr Introduction and Objecti Oduction And Objectiv Ve Ementioning

confidence: 99%

“…These tailored blanks provide material in the area where it is especially required [7] and can increase the material efficiency by processing a thinner initial blank [8]. Furthermore, the targeted adaption of mechanical properties are to be considered beneficial [8]. Several forming processes and strategies for the manufacturing of tailored blanks are available within SBMF.…”

Section: Intr Introduction and Objecti Oduction And Objectiv Ve Ementioning

confidence: 99%

“…In comparison to conventional manufacturing strategies of tailored blanks like upsetting, process limits can accordingly be extended and maximum press forces are reduced by up to 90 % [7]. This pre-forming of the sheet blanks however leads to an increase of the material's hardness [8]. As increasing hardness values have an adverse effect on further forming properties [9], a heat treatment is carried out to restore the initial microstructure and hardness [10].…”

Section: Intr Introduction and Objecti Oduction And Objectiv Ve Ementioning

confidence: 99%

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Investigation on tailored blanks in a full forward extrusion process of sheet-bulk metal forming

Reck¹,

Merklein²

2021

Esaform 2021

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Due to the ongoing technological development, the demand for geometrically complicated high performance parts with great functional density is increasing. Often, the use of sheet metal is a beneficial approach in manufacturing technology to meet the requirements on components regarding material strength and lightweight construction goals. The forming of therefore required complex sheet metal part geometries with integrated functional elements cause the need for a three dimensional material flow. Sheet-bulk metal forming, characterized by the application of bulk forming operations on sheet metals, is a suitable approach to produce such components. A challenge is the material flow control, resulting in an insufficient die filling of the functional elements. The use of tailored blanks with a defined sheet thickness distribution is an auspicious approach to face this challenge in subsequent forming processes. In the presented work, semi-finished products with a continuous thickness profile manufactured by orbital forming are applied in a full forward extrusion process. By an additional implementation of a heat treatment, the tailored blanks undergo a recrystallization process that causes a softening of the strain hardened material. In this paper, the potential of a heat treatment in the process class of sheet-bulk metal forming is shown by characterizing the geometrical and mechanical properties of the functional components by applying the mild deep drawing steel DC04 with an initial sheet thickness of t0 = 2.0 mm.

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Section: Or Orbital F Bital Forming Ormingmentioning

confidence: 99%

Section: Intr Introduction and Objecti Oduction And Objectiv Ve Ementioning

confidence: 99%

Section: Intr Introduction and Objecti Oduction And Objectiv Ve Ementioning

confidence: 99%

Section: Intr Introduction and Objecti Oduction And Objectiv Ve Ementioning

confidence: 99%

See 2 more Smart Citations

Investigation on tailored blanks in a full forward extrusion process of sheet-bulk metal forming

Reck¹,

Merklein²

2021

Esaform 2021

View full text Add to dashboard Cite

show abstract

“…Consequently, the contact zone between the tool and workpiece is reduced significantly, resulting in reduced required forming forces of 10%, compared to conventional upsetting [19]. Due to the quasi-rolling movement of the punch, the material is pushed radially outside into the desired cavities, which can be applied either into the punch or the counterpunch or both-sided, depending on the desired geometry [20]. Due to the radial material flow, a characteristic process effect is a so-called centre thinning, explaining the local thinning in the component centre [21].…”

Section: Introductionmentioning

confidence: 99%

Pin Extrusion for Mechanical Joining from Orbital Formed Tailored Blanks with Local Material Pre-Distribution

Römisch

Hetzel

Wituschek

et al. 2022

JMMP

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Pin extrusion is a common process to realise pin structures in different geometrical dimensions for a subsequent joining operation. Nevertheless, the process of pin extrusion offers process limits regarding sheet thinning as a consequence of the punch penetration depth into the sheet. Thereby, cracks at the residual sheet thickness can occur during strength tests, resulting in a failure of the complete joint due to severe thinning. Therefore, measures have to be taken into account to reduce the thinning. One possibility is the application of orbital formed tailored blanks with a local material pre-distribution, which allows a higher sheet thickness in the desired area. Within this contribution, the novel approach of a process combination of orbital forming and pin extrusion is investigated. To reveal the potential of a local material pre-distribution, conventional specimens are compared with previously orbital formed components. Relevant parameters such as the residual sheet thickness, the pin height as well as the average hardness values are compared. The results show a significant positive influence of a local material pre-distribution on the residual sheet thickness as well as the resulting pin height. Furthermore, the strain hardening during orbital forming can be seen as an additional advantage. To conclude the results, the process limits of conventional pin extrusion can be expanded significantly by the application of specimens with a local material pre-distribution.

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Functional Analysis of Components Manufactured by a Sheet-Bulk Metal Forming Process

Hetzel

Schulte

Vogel

et al. 2021

JMMP

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Due to rising demands regarding the functionality and load-bearing capacity of functional components such as synchronizer rings in gear systems, conventional forming operations are reaching their limits with respect to formability and efficiency. One way to meet these challenges is the application of the innovative process class of sheet-bulk metal forming (SBMF). By applying bulk forming operations to sheet metal, the advantages of both process classes can be combined, thus realizing an optimized part weight and an adapted load-bearing capacity. Different approaches to manufacturing relevant part geometries were presented and evaluated regarding the process properties and applicability. In this contribution, a self-learning engineering workbench was used to provide geometry-based data regarding a novel component geometry with circumferential involute gearing manufactured in an SBMF process combination of deep drawing and upsetting. Within the comprehensive investigations, the mechanical and geometrical properties of the part were analyzed. Moreover, the manufactured components were compared regarding the increased fatigue strength in cyclic load tests. With the gained experimental and numerical data, the workbench was used for the first time to generate the desired component as a CAD model, as well as to derive design guidelines referring to the investigated properties and fatigue behavior.

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Orbital Forming of Tailored Blanks for Industrial Application

Cited by 3 publications

References 13 publications

Investigation on tailored blanks in a full forward extrusion process of sheet-bulk metal forming

Investigation on tailored blanks in a full forward extrusion process of sheet-bulk metal forming

Pin Extrusion for Mechanical Joining from Orbital Formed Tailored Blanks with Local Material Pre-Distribution

Functional Analysis of Components Manufactured by a Sheet-Bulk Metal Forming Process

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