Plastic flow and its control in sheet–bulk metal forming of thin-walled functional components

Merklein, Marion; Löffler, Maria; Schneider, Thomas

doi:10.1016/j.cirp.2015.04.078

Cited by 14 publications

(6 citation statements)

References 7 publications

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“…The results shown for cups with combined functional elements are transferable to the results for cups with similar functional elements presented in [8] and [9]. Increased thinning of the material under radial tensile stress in the area of the drawing punch radius and thickening in the wall due to tangential compression…”

Section: Draw-in Behaviour and Materials Flow During Deep Drawingsupporting

confidence: 64%

“…The allocation of additional material for the functional elements shall enable an increased die filling and at the same time prevent tangential material flow and increased tool loads [9]. To adapt the blank layout the material necessary to enable a complete die filling is calculated.…”

Section: Identification Of the Blank Layoutmentioning

confidence: 99%

“…To manufacture parts with an increased functional integration the tool concepts presented in [8] for the external gearing and [9] for open carriers are combined. The tool concept consists of an upper tool with drawing die and upsetting punch and a lower tool with upsetting plate and drawing punch.…”

Section: Process Set-upmentioning

confidence: 99%

“…For the forming of both types of functional elements the material flow control is the main challenge. The external gearing is a thick-walled element which requires a large thickening of material in the gear cavity [8] whereas for the open carrier, as a thin-walled element, excessive thinning of the material has to be prevented [9]. The combination of different functional elements now takes account of the increasing demand of functional integration and is presented in figure 1.…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Interaction of various functional elements in thin-walled cups formed by a sheet-bulk metal forming process

Schulte¹,

Schneider²,

Lechner³

et al. 2016

MATEC Web Conf.

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Abstract. Sheet-bulk metal forming allows the manufacturing of sheet metal parts with integrated functional elements. The investigated process combines deep drawing and upsetting. The occurring 2D and 3D stress and strain states lead to challenges regarding material flow control due to different geometries of functional elements. The numerical analysis shows the transferability for the results of the different functional elements for the ir combination and the interaction between those functional elements regarding the material flow. The results are validated by experimental tests.

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Section: Draw-in Behaviour and Materials Flow During Deep Drawingsupporting

confidence: 64%

Section: Identification Of the Blank Layoutmentioning

confidence: 99%

Section: Process Set-upmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Interaction of various functional elements in thin-walled cups formed by a sheet-bulk metal forming process

Schulte¹,

Schneider²,

Lechner³

et al. 2016

MATEC Web Conf.

Self Cite

View full text Add to dashboard Cite

show abstract

“…For example, Feldhaus [8] combined two-dimensional analytical and three-dimensional finite element modelling to optimize the geometry of the rolls and to ensure an adequate material flow to produce riblet sheet surfaces. Merklein et al [9] investigated the use of tailored blank layouts and surfaces to improve the filling behaviour of a deep drawn cup-shaped part whose geometry is calibrated by upsetting perpendicular to the sheet plane.…”

Section: Introductionmentioning

confidence: 99%

Incipient and repeatable plastic flow in incremental sheet-bulk forming of gears

Sieczkarek

Wernicke

Gies

et al. 2016

Int J Adv Manuf Technol

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This paper analyses the differences between incipient and repeatable material flow in the incremental sheet-bulk metal forming (SBMF) of gears produced by indentation along the direction perpendicular to the sheet thickness. The underfilling of the punch cavity during the first indentation, which prevents the production of sound disk gears, is explained on the basis of constrained material flow under material strain hardening. A solution based on the utilization of a tailored disk blank is proposed to overcome this defect. The geometry of the tailored disk blank is determined by means of finite element analysis, and the overall methodology involved material characterization and experimentation with DC04 mild steel. The discussion on the extent of the plastic deformation region under constrained and free-material flow during indentation is complemented by experimental results obtained with a flat punch in rectangular sheet blanks of aluminium EN AW-1050A.

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Tool Sided Surface Modifications in the Industrial Environment

Wild

Merklein

2020

Lecture Notes in Production Engineering

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Plastic flow and its control in sheet–bulk metal forming of thin-walled functional components

Cited by 14 publications

References 7 publications

Interaction of various functional elements in thin-walled cups formed by a sheet-bulk metal forming process

Interaction of various functional elements in thin-walled cups formed by a sheet-bulk metal forming process

Incipient and repeatable plastic flow in incremental sheet-bulk forming of gears

Tool Sided Surface Modifications in the Industrial Environment

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