Material Flow in Sheet-Bulk Metal Forming

Ulrich Vierzigmann; Johannes Koch; Marion Merklein; Ulf Engel

doi:10.4028/www.scientific.net/KEM.504-506.1035

Paper Titles

Maturity Model for the Development of New Forming Processes Applied to the Sheet-Bulk Metal Forming
p.1011

Temperature Control during the APN-Process on the Steel 1.3343
p.1017

Manufacturing of Sheet Metal Components with Variants Using Process Adapted Semi-Finished Products
p.1023

Material Characterization for Sheet-Bulk Metal Forming
p.1029

Material Flow in Sheet-Bulk Metal Forming
p.1035

Analysis of Roll Gap Heat Transfers in Hot Steel Strip Rolling through Roll Temperature Sensors and Heat Transfer Models
p.1043

Cooling of a Rotating Cylinder by a Subcooled Planar Jet - Influence of the Surface Velocity on Boiling Regime
p.1049

Implementation of the Axially Symmetrical and Three Dimensional Finite Element Models to the Determination of the Heat Transfer Coefficient Distribution on the Hot Plate Surface Cooled by the Water Spray Nozzle
p.1055

Determination of Heat Repartition Parameters on High Speed Pin-on-Disc Tribometer by Inverse Heat Conduction Method
p.1061

HomeKey Engineering MaterialsKey Engineering Materials Vols. 504-506Material Flow in Sheet-Bulk Metal Forming

Material Flow in Sheet-Bulk Metal Forming

Abstract:

Innovative trends like increasing component functionality, the demand for automotive lightweight constructions and the economic issue to optimize existing process chains, require new ways in manufacturing. Today, the traditional sheet metal and bulk metal forming processes are often reaching their limits if closely-tolerated complex functional components with variants have to be produced. A promising approach is the direct forming of high-precision shapes starting from blanks. Thus, classic sheet metal forming operations, such as deep drawing, are combined with bulk metal forming operations like extrusion of complex variants as for example teeth. This combination of sheet and bulk metal forming operations leads to a side by side situation of different tribological conditions according to the locally varying load situations within the same forming process. This new class of forming processes is defined as sheet-bulk metal forming (SBMF). The tribological conditions in sheet-bulk metal forming processes are of major importance for the process realization, its stability and for the quality of the produced part. The objective of this paper is the investigation of material flow in SBMF in general and the attempt to improve the material flow by local adapted tribological conditions. First the material flow was analyzed by FE-simulation of a model geometry that is typical for SBMF. The investigations with FE-simulation have shown, locally adapted tribological conditions are leading to an improvement in material flow and thus to an increased mould filling. As frictional conditions are directly connected to the topography of workpiece and tool, the modification of the workpiece topography is leading to an alteration in friction values. For the modification of workpiece topography grit blasting was used. The increase in friction of grit blasted surface towards untreated surface was investigates by using the laboratory friction tests. To manufacture specimens with locally adapted topographies for forming tests a masking technique has been developed. The masks are designed after the preliminary findings determined by FE-simulation.

You might also be interested in these eBooks

View Preview

Info:

Periodical:

Key Engineering Materials (Volumes 504-506)

Pages:

1035-1040

DOI:

https://doi.org/10.4028/www.scientific.net/KEM.504-506.1035

Citation:

Cite this paper

Online since:

February 2012

Authors:

Ulrich Vierzigmann, Johannes Koch, Marion Merklein, Ulf Engel

Keywords:

Abrasive Blasting, Material Flow, Sheet-Bulk-Metal Forming, Tribology

Export:

RIS, BibTeX

Price:

Permissions:

Request Permissions

References

[1] M. Merklein, J. Koch, S. Opel, T. Schneider, Fundamental investigations on the material flow at combined sheet and bulk metal forming processes, CIRP Annals, 60/1 (2011), pp.283-286.

DOI: 10.1016/j.cirp.2011.03.146

Google Scholar

[2] H. Hetzner, J. Koch, S. Tremmel, S. Wartack, M. Merklein, Improved Sheet-Bulk Metal Forming Processes by Local Adjustment of Tribological Properties. Journal of Manufacturing Science and Engineering, 133(2012)6, in print.

DOI: 10.1115/1.4005313

Google Scholar

[3] U. Vierzigmann, M. Merklein, U. Engel, Tailored Surfaces in Sheet-Bulk Metal Forming, in: Felder, F.; Montmitonnet, P. (edtrs): Tribology Of Manufacturing Processes. Proc. 4th ICTMP Int. Conf. on Tribology im Manuf. Processes, Jun 13-15, 2010, Nice, France, Transvalor - Presses des Mines 2010, Vol. II, pp.541-550.

Google Scholar

[4] U. Vierzigmann, M. Merklein, U. Engel, Friction Conditions in Sheet-Bulk Metal Forming, in: Proceedia Engineering, in: Procedia Engineering, 19 (2011), pp.377-382.

DOI: 10.1016/j.proeng.2011.11.128

Google Scholar

[5] S. Weidel, U. Engel, Surface characterization in forming processes by functional parameters. Int. J. Adv. Manuf. Technol. 33(2007)1-2, pp.130-136.

DOI: 10.1007/s00170-006-0644-x

Google Scholar