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Manufacturing of functional elements by sheet-bulk metal forming processes

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Abstract

Due to increasing economic and ecological restrictions, conventional sheet and bulk forming operations often reach their limits with regard to part weight and functional integration. One solution to meet those challenges is provided by sheet-bulk metal forming (SBMF) processes. SBMF is defined as the application of bulk forming operations on sheet metal. SBMF can be combined with conventional sheet forming operations and offers the opportunity to form highly functional integrated parts out of sheet metal. It contains the benefit of an optimization of the part weight and a shortening of the process chain. Recent research has found different solutions regarding the actual implementation of SBMF in several process variants. In this paper, a categorisation for functional elements on sheet metal parts is proposed. A selection of possible approaches for their manufacturing is presented. The process variants are compared by means of the main process characteristics. By these means, the choice of a suitable option shall be facilitated for practical manufacturing design and for a particular relevant product.

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Acknowledgments

This work was supported by the German Research Foundation (DFG) within the scope of the Transregional Collaborative Research Centre on Sheet-Bulk metal forming (SFB/TR 73). It has been created in particular with the help of the Subprojects A1, A2, A4 and A7. Furthermore special thanks go to the research group “part properties” which is also active in the context of the TR 73 research compound.

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Authors and Affiliations

  1. Institute of Manufacturing Technology, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Egerlandstraße 11 - 13, 91058, Erlangen, Germany

    D. Gröbel, R. Schulte, P. Hildenbrand, M. Lechner, U. Engel & M. Merklein

  2. Institute of Forming Technology and Lightweight Construction, TU Dortmund University, Dortmund, Germany

    P. Sieczkarek, S. Wernicke, S. Gies & A. E. Tekkaya

  3. Institute of Forming Technology and Machines, Leibniz Universität Hannover, Hannover, Germany

    B. A. Behrens, S. Hübner, M. Vucetic & S. Koch

Authors
  1. D. Gröbel
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  2. R. Schulte
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  3. P. Hildenbrand
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  4. M. Lechner
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  5. U. Engel
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  6. P. Sieczkarek
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  7. S. Wernicke
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  8. S. Gies
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  9. A. E. Tekkaya
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  10. B. A. Behrens
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  11. S. Hübner
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  12. M. Vucetic
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  13. S. Koch
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  14. M. Merklein
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Correspondence to D. Gröbel.

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Gröbel, D., Schulte, R., Hildenbrand, P. et al. Manufacturing of functional elements by sheet-bulk metal forming processes. Prod. Eng. Res. Devel. 10, 63–80 (2016). https://doi.org/10.1007/s11740-016-0662-y

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  • DOI: https://doi.org/10.1007/s11740-016-0662-y

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