TY - JOUR

T1 - Influence of Tailored Surfaces and Superimposed-Oscillation on Sheet-Bulk Metal Forming Operations

AU - Behrens, Bernd Arno

AU - Tillmann, Wolfgang

AU - Biermann, Dirk

AU - Hübner, Sven

AU - Stangier, Dominic

AU - Freiburg, Dennis

AU - Meijer, Alexander

AU - Koch, Sergej

AU - Rosenbusch, Daniel

AU - Müller, Philipp

N1 - Funding information: The authors gratefully acknowledge the financial support of the German Research Foundation (DFG) within the transregional collaborative research center TR73 “Manufacturing of complex functional components with variants by using a new sheet metal forming process—Sheet Bulk Metal Forming” projects A7-116817829 (“Dynamic Process Forces”), B3 (“Generation of predetermined surface structures by intentionally invoked self-excited tool vibrations when milling free-formed surfaces”) and B5 (“Application of nanostructured bionic thin layers to enhance the wear and friction behavior of forming tools by thin-walled sheet forming”).

PY - 2020/4/29

Y1 - 2020/4/29

N2 - Producing complex sheet metal components in fewer process steps motivated the development of the innovative forming process called sheet-bulk metal forming (SBMF). In this process, sheet metal forming and bulk-metal forming are combined to create a unique forming process in which a component with external and internal gearing is produced in three production steps. However, the high degrees of deformation that occur using high-strength steels and the number of different process steps result in high process forces, strongly limiting the service life of tools. To reduce the forming force during SBMF processes, tool and process modifications were investigated. Therefore, plane-strain compression tests were conducted to examine the influence of a CrAlN PVD coating and tailored surfaces produced by high-feed milling (HF) of tool-active elements on the material flow of the specimens. In addition to the tool-sided modifications, the influence of an oscillation overlay during the forming process was investigated. Based on the results of the compression tests, the surfaces of the active tool elements of the SBMF process were modified in order to transfer the basic experimental results to the production of a functional component. The friction is thus adapted locally in the SBMF process.

AB - Producing complex sheet metal components in fewer process steps motivated the development of the innovative forming process called sheet-bulk metal forming (SBMF). In this process, sheet metal forming and bulk-metal forming are combined to create a unique forming process in which a component with external and internal gearing is produced in three production steps. However, the high degrees of deformation that occur using high-strength steels and the number of different process steps result in high process forces, strongly limiting the service life of tools. To reduce the forming force during SBMF processes, tool and process modifications were investigated. Therefore, plane-strain compression tests were conducted to examine the influence of a CrAlN PVD coating and tailored surfaces produced by high-feed milling (HF) of tool-active elements on the material flow of the specimens. In addition to the tool-sided modifications, the influence of an oscillation overlay during the forming process was investigated. Based on the results of the compression tests, the surfaces of the active tool elements of the SBMF process were modified in order to transfer the basic experimental results to the production of a functional component. The friction is thus adapted locally in the SBMF process.

KW - Oscillation superimposition

KW - Plane-strain compression tests

KW - Sheet-bulk metal forming

KW - Tailored surfaces

UR - http://www.scopus.com/inward/record.url?scp=85086408052&partnerID=8YFLogxK

U2 - 10.3390/jmmp4020041

DO - 10.3390/jmmp4020041

M3 - Article

AN - SCOPUS:85086408052

VL - 4

JO - Journal of Manufacturing and Materials Processing

JF - Journal of Manufacturing and Materials Processing

IS - 2

ER -