TY - JOUR

T1 - Functional analysis of components manufactured by a sheet-bulk metal forming process

AU - Hetzel, Andreas

AU - Schulte, Robert

AU - Vogel, Manfred

AU - Lechner, Michael

AU - Besserer, Hans Bernward

AU - Maier, Hans Jürgen

AU - Sauer, Christopher

AU - Schleich, Benjamin

AU - Wartzack, Sandro

AU - Merklein, Marion

N1 - Funding Information: Acknowledgments: This study was supported by the German Research Foundation (DFG) within the scope of the Transregional Collaborative Research Centre on Sheet-Bulk metal forming (TCRC 73). It has been realized in particular with the help of the subprojects A1, B1, C6, and T02. Furthermore, special thanks go to the research group “Component Properties and Function” which is also active in the context of the TCRC 73 research compound. Funding: This work is funded within the scope of the Transregional Collaborative Research Centre TCRC73 by the German Research Foundation under Grant number TRR73-68237143.

PY - 2021/6

Y1 - 2021/6

N2 - 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.

AB - 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.

KW - Fatigue life modeling

KW - Functional behavior

KW - Mechanical properties

KW - Self-learning engineering workbench

KW - Sheet-bulk metal forming

KW - Z-integral approach

UR - http://www.scopus.com/inward/record.url?scp=85106922387&partnerID=8YFLogxK

U2 - 10.3390/jmmp5020049

DO - 10.3390/jmmp5020049

M3 - Article

AN - SCOPUS:85106922387

VL - 5

JO - Journal of Manufacturing and Materials Processing

JF - Journal of Manufacturing and Materials Processing

IS - 2

M1 - 49

ER -