Sheet Bulk Forming of Thin-Walled Components with External Gearing through Upsetting Using Controllable Deformation Zone Method

Abstract

Sheet-bulk metal forming (SBMF) is a promising process for manufacturing complex sheet components with functional elements. In this study, the entire forming process for a typical thin-walled component with external gearing is investigated, including sheet forming and bulk forming processes. Deep drawn cups are prepared during sheet forming; subsequently, upsetting is performed on the sidewall to form external gearing. The upsetting method performed is known as upsetting with a controllable deformation zone (U-CDZ). Compared with the conventional upsetting method, a floating counter punch with a counter force is used in the U-CDZ method such that the forming mechanism is changed into the accumulation of the deformation zone instead of deformation throughout the entire sidewall. The effects of the counter force and material flow are investigated to understand the mechanism. The forming quality, i.e., the formfilling and effective strain distribution, improved, whereas a high forming load is avoided. In addition, a punch with a lock bead is used to prevent folding at the inner corner during the experiment.

Analysis of a New Process for Forming Two Flanges Simultaneously in a Hollow Part by Extrusion with Two Moving Dies

“…The technique could be employed to forming flanges both on product end and in its centre [19]. It could also be used as a finishing operation in upsetting cups with increased wall thickness [20] or components with external gearing [21]. A study [22] showed that the forming force was nearly constant during the process.…”

Deformation response of 6061 aluminum alloy in multi-bosses forming by plate forging at elevated temperature

“…Wang et al (2019) applied the flow model in metal cutting to cold forging of tubular products. As reported by Zhuang et al (2019Zhuang et al ( , 2021 and Hsu et al (2021), the controllable deformation zone method could be adopted to manufacture thin-walled components with gear and flange features, and copper heat spreader with high quality. Wang et al (2013) proposed a new process, namely compressiondrawing method, to manufacture central bosses on the bottom of a cup with a lower forming load, which may provide a valuable solution for the fabrication of local features such as gears and small corners.…”