Functional Analysis of Components Manufactured by a Sheet-Bulk Metal Forming Process
Hetzel A, Schulte RK, Vogel M, Lechner M, Besserer HB, Maier HJ, Sauer C, Schleich B, Wartzack S, Merklein M (2021)
Publication Language: English
Publication Type: Journal article, Original article
Publication year: 2021
Journal
Book Volume: 5
Pages Range: 1-18
Article Number: 49
Journal Issue: 2
DOI: 10.3390/jmmp5020049
Open Access Link: https://www.mdpi.com/2504-4494/5/2/49
Abstract
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.
Authors with CRIS profile
Andreas Hetzel
Sonderforschungsbereich/Transregio 73 Umformtechnische Herstellung von komplexen Funktionsbauteilen mit Nebenformelementen aus Feinblechen - Blechmassivumformung
Robert Karl Schulte
Institute of Manufacturing Technology
Manfred Vogel
Institute of Manufacturing Technology
Michael Lechner
Institute of Manufacturing Technology
Christopher Sauer
Chair of Engineering Design
Benjamin Schleich
Chair of Engineering Design
Sandro Wartzack
Chair of Engineering Design
Marion Merklein
Institute of Manufacturing Technology
Related research project(s)
Development of a forming process to manufacture near-net-shape functional components with a gradient in sheet thickness (SFB/TR 73 T10)
TRR 73: Manufacturing of complex functional components with variants by using a new sheet metal forming process - Sheet-Bulk Metal Forming
Jan. 1, 2021 - Sept. 30, 2023
Manufacturing of tailored blanks by orbital forming and flexible rolling (SFB/TR73 - A1/1)
Umformtechnische Herstellung von komplexen Funktionsbauteilen mit Nebenformelementen aus Feinblechen - Blechmassivumformung
Jan. 1, 2016 - March 31, 2021
Orbital forming of Tailored Blanks for industrial application
TRR 73: Manufacturing of complex functional components with variants by using a new sheet metal forming process - Sheet-Bulk Metal Forming
Jan. 1, 2019 - March 31, 2021
Involved external institutions
Germany (DE)How to cite
APA:
Hetzel, A., Schulte, R.K., Vogel, M., Lechner, M., Besserer, H.-B., Maier, H.J.,... Merklein, M. (2021). Functional Analysis of Components Manufactured by a Sheet-Bulk Metal Forming Process. Journal of Manufacturing and Materials Processing, 5(2), 1-18. https://dx.doi.org/10.3390/jmmp5020049
MLA:
Hetzel, Andreas, et al. "Functional Analysis of Components Manufactured by a Sheet-Bulk Metal Forming Process." Journal of Manufacturing and Materials Processing 5.2 (2021): 1-18.
BibTeX: Download