Grundlegende Untersuchungen zur Herstellung von Funktionsbauteilen vom Band
Start: 1. January 2022
Ende: 31. December 2023
The application of bulk forming processes to sheet metal, also known as sheet-bulk metal forming, extends the existing forming limits of established sheet and bulk forming processes. This enables the resource-efficient production of functionally integrated lightweight components. In previous research, sheet-bulk metal forming of pre-cut blanks was investigated. By using coil as semi-finished products, the advantages of manufacturing from coil in terms of simplified component handling and as a result higher output quantity are combined with the advantages of sheet-bulk metal forming in terms of extended forming limits.
The usage of coils, however, results in an anisotropic material flow and consequently an unequal shape of the formed components. This worsens the component application behavior and is especially a challenge for cyclically symmetrical parts. In addition asymmetrical tool loads, critical for fatigue, occur. Considering this, the objective is to elaborate a process understanding for extrusion of gears from coil. It should be investigated how the anisotropic material flow affects the forming of the individual functional elements of cyclically symmetrical components and the tool loads.In order to increase the application potential of extrusion of gears from coil, another objective is to provide measures to reduce the anisotropic material flow and to improve the geometrical accuracy of formed parts. For this purpose, different approaches for material flow control, such as adjusting the coil width, feed width, tool geometry and local adaptation of friction should be analyzed for cyclically symmetrical parts. In addition to the effectiveness, the wear-behavior of the measures has to be investigated in tool life tests.
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