Details
| Original language | English |
|---|---|
| Pages (from-to) | 37-50 |
| Number of pages | 14 |
| Journal | Production Engineering |
| Volume | 10 |
| Issue number | 1 |
| Publication status | Published - 7 Jan 2016 |
Abstract
Sheet-Bulk Metal Forming (SBMF) allows the manufacture of complex parts with integrated functional form elements, such as teeth and thickened areas. Therefore, bulk forming operations are applied to sheets with initial thicknesses of 2 or 3 mm. The design and functionality of the tools are as important as the process itself. Therefore, the working group “Tools” of the Transregional Collaborative Research Centre on Sheet-Bulk Metal Forming (CRC/TR73) focuses on the optimization of the technical tool design. By varying topographies or applying tailored coatings, the friction behavior is changed to achieve a better form filling and to reduce process forces during the forming operations. In this paper, the potential of different tailored surfaces is validated by simulations and experimental studies. The tribological behavior of 14 surface microstructures is evaluated using a half-space model in order to select structures suitable for application. Those were characterized experimentally by ring-compression and pin-extrusion tests. The determined friction factors were used in a forming simulation to predict the form filling of small cavities in a flow forming operation. Furthermore, special attention is paid to the utilization of the anisotropic behavior of specific structures. The results were validated by an incremental gear forming process.
Keywords
- Coating technologies, Forming simulations, Milling technologies, Sheet-Bulk Metal Forming, Tailored surfaces, Tribology simulation
ASJC Scopus subject areas
- Engineering(all)
- Mechanical Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Production Engineering, Vol. 10, No. 1, 07.01.2016, p. 37-50.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Experimental and numerical analysis of tribological effective surfaces for forming tools in Sheet-Bulk Metal Forming
AU - Kersting, Petra
AU - Gröbel, Daniel
AU - Merklein, Marion
AU - Sieczkarek, Peter
AU - Wernicke, Sebastian
AU - Tekkaya, A. Erman
AU - Krebs, Eugen
AU - Freiburg, Dennis
AU - Biermann, Dirk
AU - Weikert, Tim
AU - Tremmel, Stephan
AU - Stangier, Dominic
AU - Tillmann, Wolfgang
AU - Matthias, Steffen
AU - Reithmeier, Eduard
AU - Löffler, Maria
AU - Beyer, Florian
AU - Willner, Kai
PY - 2016/1/7
Y1 - 2016/1/7
N2 - Sheet-Bulk Metal Forming (SBMF) allows the manufacture of complex parts with integrated functional form elements, such as teeth and thickened areas. Therefore, bulk forming operations are applied to sheets with initial thicknesses of 2 or 3 mm. The design and functionality of the tools are as important as the process itself. Therefore, the working group “Tools” of the Transregional Collaborative Research Centre on Sheet-Bulk Metal Forming (CRC/TR73) focuses on the optimization of the technical tool design. By varying topographies or applying tailored coatings, the friction behavior is changed to achieve a better form filling and to reduce process forces during the forming operations. In this paper, the potential of different tailored surfaces is validated by simulations and experimental studies. The tribological behavior of 14 surface microstructures is evaluated using a half-space model in order to select structures suitable for application. Those were characterized experimentally by ring-compression and pin-extrusion tests. The determined friction factors were used in a forming simulation to predict the form filling of small cavities in a flow forming operation. Furthermore, special attention is paid to the utilization of the anisotropic behavior of specific structures. The results were validated by an incremental gear forming process.
AB - Sheet-Bulk Metal Forming (SBMF) allows the manufacture of complex parts with integrated functional form elements, such as teeth and thickened areas. Therefore, bulk forming operations are applied to sheets with initial thicknesses of 2 or 3 mm. The design and functionality of the tools are as important as the process itself. Therefore, the working group “Tools” of the Transregional Collaborative Research Centre on Sheet-Bulk Metal Forming (CRC/TR73) focuses on the optimization of the technical tool design. By varying topographies or applying tailored coatings, the friction behavior is changed to achieve a better form filling and to reduce process forces during the forming operations. In this paper, the potential of different tailored surfaces is validated by simulations and experimental studies. The tribological behavior of 14 surface microstructures is evaluated using a half-space model in order to select structures suitable for application. Those were characterized experimentally by ring-compression and pin-extrusion tests. The determined friction factors were used in a forming simulation to predict the form filling of small cavities in a flow forming operation. Furthermore, special attention is paid to the utilization of the anisotropic behavior of specific structures. The results were validated by an incremental gear forming process.
KW - Coating technologies
KW - Forming simulations
KW - Milling technologies
KW - Sheet-Bulk Metal Forming
KW - Tailored surfaces
KW - Tribology simulation
UR - http://www.scopus.com/inward/record.url?scp=84957842111&partnerID=8YFLogxK
U2 - 10.1007/s11740-015-0651-6
DO - 10.1007/s11740-015-0651-6
M3 - Article
AN - SCOPUS:84957842111
VL - 10
SP - 37
EP - 50
JO - Production Engineering
JF - Production Engineering
SN - 0944-6524
IS - 1
ER -