Potential of Orbital Formed Tailored Blanks for Industrial Application

Hetzel A, Lechner M, Aman A, Büdicker K, Merklein M (2022)

Publication Language: English

Publication Type: Conference contribution, Conference Contribution

Publication year: 2022

Pages Range: 1-8

Event location: Milano IT

Abstract

Due to economic and ecologic framework conditions like fuel reduction or sustainability, the manufacturing industry is facing greater challenges than ever before. One way to meet these challenges is the combination of lightweight construction and functional integration with an increased material efficiency. Nowadays, components like synchronizer rings or clutch plates are manufactured by machining, producing scrap and thus reducing the efficiency drastically. Orbital forming is an innovative manufacturing process, providing the possibility to efficiently produce functional components with a varying sheet thickness. Thereby, a tumbling motion of the punch reduces the contact area between workpiece and tool, thus enabling a significantly lower process force. The material distribution is realized by a tangential and radial material flow into the cavities. Until now, orbital formed Tailored Blanks have only been investigated as semi-finished products used in a single-stage process combination of deep drawing and upsetting. With regard on the potential for an industrial application, a Tailored Blank layout with different functional elements is introduced. The demonstrator for this investigation is manufactured out of the case-hardenable steel C10 and is depicting a clutch disc carrier with both-sided cyclic as well as rotational-symmetric material thickenings. To evaluate the industrial applicability, the components are analyzed regarding their geometrical and mechanical properties and are compared to the target contour. To demonstrate the operational advantages of the orbital formed components in comparison to conventionally manufactured parts, the fatigue life is evaluated as indicator for the functional behavior.

Authors with CRIS profile

Andreas Hetzel Institute of Manufacturing Technology Michael Lechner Institute of Manufacturing Technology 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

Involved external institutions

ZF Friedrichshafen AG DE Germany (DE)

How to cite

APA:

Hetzel, A., Lechner, M., Aman, A., Büdicker, K., & Merklein, M. (2022). Potential of Orbital Formed Tailored Blanks for Industrial Application. In Proceedings of the Steel in Cars and Trucks (SCT) (pp. 1-8). Milano, IT.

MLA:

Hetzel, Andreas, et al. "Potential of Orbital Formed Tailored Blanks for Industrial Application." Proceedings of the Steel in Cars and Trucks (SCT), Milano 2022. 1-8.

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