Manufacturing of tailored blanks by orbital forming with a two-sided material thickening

Vogel M, Merklein M (2019)

Publication Type: Journal article

Publication year: 2019


Article Number: 116491

DOI: 10.1016/j.jmatprotec.2019.116491


Due to the rising lightweight construction, especially in the automotive industry, the demands focused on functional components are constantly increasing with a result of new challenges regarding the manufacturing technology. For an extension of the process limits of conventional sheet metal forming processes, semi-finished parts with a defined material pre-distribution, so-called tailored blanks, can be used to provide additional material volume in defined areas in order to achieve a proper die filling of functional elements like gearings or carriers used e.g. for synchronizer rings. However, due to the increasing component complexity and thus the forming of functional elements on both sides of the frame, a two-sided thickness profile is mandatory. As a result, the material thickenings on both sides of the tailored blank lead to an interaction, regarding the maximum achievable sheet thicknesses or dimensions of the material pre-distribution. For the manufacturing of such tailored blanks, an orbital forming process can be used. Prior investigations showed the general feasibility for the manufacturing of tailored blanks with a one-sided thickness profile. In this paper, the feasibility of using the orbital forming process to produce tailored blanks is fundamentally investigated. Therefore, a numerical model of the process was developed, with a subsequent validation by comparing the numerical with the experimental results. Afterwards, the material flow is analysed regarding different geometries of the material pre-distribution as well as the position of the thickness profile in order to allow a generally valid design.

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Vogel, M., & Merklein, M. (2019). Manufacturing of tailored blanks by orbital forming with a two-sided material thickening. Journal of Materials Processing Technology.


Vogel, Manfred, and Marion Merklein. "Manufacturing of tailored blanks by orbital forming with a two-sided material thickening." Journal of Materials Processing Technology (2019).

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