Investigation of tailored tool surfaces for improving the component quality of sheet-bulk metal forming parts produced by a combined deep-drawing and upsetting process

Henneberg J, Schulte RK, Merklein M (2022)

Publication Language: English

Publication Type: Conference contribution, Conference Contribution

Publication year: 2022

Pages Range: 1-6

Conference Proceedings Title: SCT Conference Proceedings

Event location: Mailand IT

Abstract

Nowadays the automotive industry is confronted with increasing demands for lightweight components with integrated functional elements, as they are for instance used as synchronizers in gearboxes. Established manufacturing processes like sheet metal forming are limited producing such parts. Therefore, the innovative manufacturing technology sheet-bulk metal forming is investigated. By the application of bulk forming operations to sheet metals, functionally integrated parts can be produced in an efficient way. In this research, a combined deep-drawing and upsetting process is analyzed to form components with involute external gears. The reduced die filling of the gears is identified as a major challenge. Consequently, this research aims to increase the die filling of the gears through tool-sided adaptions. For analyzing the cause of the reduced die filling, a numerical process model is built up and validated. By analyzing this model, an undesired material flow from the functional elements to the center of the part is identified. In a next step, the potential of material flow control by global and local adaptation of the friction is numerically investigated. For this, the friction factor is varied between 0.1 and 0.5 in different areas. The numerical results indicate that by locally adjusting the friction, the material flow can be controlled and thus the shape of the gearing can be improved. Based on the numerical findings, tailored friction systems are implemented in an experimental setup. The tool surfaces are locally modified by an abrasive blasting process. Hereby, the friction is tailored according to the numerically determined requirements. Concluding, the applicability of tailored tool surfaces for material flow control and improvement of component quality is experimentally shown.

Authors with CRIS profile

Johannes Henneberg Institute of Manufacturing Technology Robert Karl Schulte Institute of Manufacturing Technology Marion Merklein Institute of Manufacturing Technology

Additional Organisation(s)

Institute of Manufacturing Technology

Related research project(s)

Constitutive friction law for the description and optimization of tailored surfaces TRR 73: Manufacturing of complex functional components with variants by using a new sheet metal forming process - Sheet-Bulk Metal Forming Jan. 1, 2009 - March 31, 2021 Process combination for manufacturing of teethed, thin-walled functional components out of tailored blanks (A01) TRR 73: Manufacturing of complex functional components with variants by using a new sheet metal forming process - Sheet-Bulk Metal Forming Jan. 1, 2009 - Jan. 1, 2012

How to cite

APA:

Henneberg, J., Schulte, R.K., & Merklein, M. (2022). Investigation of tailored tool surfaces for improving the component quality of sheet-bulk metal forming parts produced by a combined deep-drawing and upsetting process. In SCT Conference Proceedings (pp. 1-6). Mailand, IT.

MLA:

Henneberg, Johannes, Robert Karl Schulte, and Marion Merklein. "Investigation of tailored tool surfaces for improving the component quality of sheet-bulk metal forming parts produced by a combined deep-drawing and upsetting process." Proceedings of the 6th international Conference on Steels in Cars and Trucks, Mailand 2022. 1-6.

BibTeX: Download