Inclusion of hot stamping operations in progressive-die plate forging of tailored high strength gear part

  • Ken-ichiro Mori
  • Tomoyoshi Maeno
  • Makoto Tsuchiya
  • Tatsuhiro Nanya
ORIGINAL ARTICLE

Abstract

Hot stamping operations of a quenchable steel sheet were included in progressive-die plate forging to produce a tailored high strength gear part without additional heat treatments. As process design for the inclusion, the former stages in the progressive-die operations for punching and trimming were cold stamping, and subsequently, resistance heating, blanking, forging and die quenching were performed. The plate was partially resistance-heated with a pair of electrodes to produce a tailored gear part having high strength teeth and a ductile remainder. The tooth portion was uniformly heated around 1050 °C in the transversal current direction, and a gear part having teeth having 520 HV2 in hardness was produced. The quality of the teeth was improved by hot semi-blanking with local compression and cold scrap removing. It is found that the combined process of plate forging and hot stamping is useful to produce ultra-high strength steel parts.

Keywords

Plate forging Hot stamping Tailored part Progressive dies Partial heating Die quenching 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Nakano T (2009) Introduction of flow control forming (FCF) for sheet forging and new presses. Proceedings of the International Seminar on Precision Forging, Kyoto, Japan, 2009, pp. 35–40Google Scholar
  2. 2.
    Merklein M, Allwood JM, Behrens BA, Brosius A, Hagenah H, Kuzman K, Mori K, Tekkaya AE, Weckenmann A (2012) Bulk forming of sheet metal. CIRP Ann Manuf Technol 61(2):725–745CrossRefGoogle Scholar
  3. 3.
    Vierzigmann HU, Merklein M, Engel U (2011) Friction conditions in sheet-bulk metal forming. Procedia Engineering 19:377–382CrossRefGoogle Scholar
  4. 4.
    Wu HC, Altan T (2014) Process optimization in stamping—a case study for flanging a clutch hub from steel plate. J Mater Process Technol 146:8–19CrossRefGoogle Scholar
  5. 5.
    Sun X, Zhu S, Zhuang X, Zhao Z (2016) Numerical investigation on tooth filling of clutch drum forming processes. Prod Eng 10(1):25–35CrossRefGoogle Scholar
  6. 6.
    Gröbel D, Schulte R, Hildenbrand P, Lechner M, Engel U, Sieczkarek P, Wernicke S, Gies S, Tekkaya AE, Behrens BA, Hübner S, Vucetic M, Koch S, Merklein M (2016) Manufacturing of functional elements by sheet-bulk metal forming processes. Prod Eng 10(1):63–80CrossRefGoogle Scholar
  7. 7.
    Isik K, Gerstein G, Schneider T, Schulte R, Rosenbusch D, Clausmeyer T, Nürnberger F, Vucetic M, Koch S, Hübner S, Behrens BA, Tekkaya AE, Merklein M (2016) Investigations of ductile damage during the process chains of toothed functional components manufactured by sheet-bulk metal forming. Prod Eng 10(1):5–15CrossRefGoogle Scholar
  8. 8.
    Matthias S, Loderer A, Koch S, Gröne M, Kästner M, Hübner S, Krimm R, Reithmeier E, Hausotte T, Behrens BA (2016) Metrological solutions for an adapted inspection of parts and tools of a sheet-bulk metal forming process. Prod Eng 10(1):51–61CrossRefGoogle Scholar
  9. 9.
    Sieczkarek P, Isik K, Khalifa NB, Martins PAF, Tekkaya AE (2014) Mechanics of sheet-bulk indentation. J Mater Process Technol 214(11):2387–2394CrossRefGoogle Scholar
  10. 10.
    Mori K, Maeno T, Fukui Y (2011) Spline forming of ultra-high strength gear drum using resistance heating of side wall of cup. CIRP Ann Manuf Technol 60(1):299–302CrossRefGoogle Scholar
  11. 11.
    Naganathan A, Penter L (2012) Chapter 7, Hot stamping. Sheet metal forming—processes and applications. in Altan, T., Tekkaya A.E. (Eds.), 133–156Google Scholar
  12. 12.
    Merklein M, Wieland M, Lechner M, Bruschi S, Ghiotti A (2016) Hot stamping of boron steel sheets with tailored properties: a review. J Mater Process Technol 228:11–24CrossRefGoogle Scholar
  13. 13.
    Engels H, Schalmin O, Müller-Bollenhagen C (2006) Controlling and monitoring of the hot-stamping process of boron-alloyed heat-treated steels. Proceedings of International Conference on New Development in Sheet Metal Forming Technology, Stuttgart, Germany, pp.135–150Google Scholar
  14. 14.
    Mori K, Maki S, Tanaka Y (2005) Warm and hot stamping of ultra high tensile strength steel sheets using resistance heating. CIRP Ann Manuf Technol 54(1):209–212CrossRefGoogle Scholar
  15. 15.
    Kolleck R, Veit R, Merklein M, Lechler J, Geiger M (2009) Investigation on induction heating for hot stamping of boron alloyed steels. CIRP Ann Manuf Technol 58(1):275–278CrossRefGoogle Scholar
  16. 16.
    Behrens BA, Hübner S, Demir M (2008) Conductive heating system for hot sheet metal forming. Proceedings of 1st International Conference on Hot Sheet Metal Forming of High-Performance Steel, Kassel, Germany, pp. 63–68Google Scholar
  17. 17.
    Ozturk F, Ece RE, Polat N, Koksal A, Evis Z, Polat A (2013) Mechanical and microstructural evaluations of hot formed titanium sheets by electrical resistance heating process. Mater Sci Eng A 578:207–214CrossRefGoogle Scholar
  18. 18.
    Liang W, Liu Y, Zhu B, Zhou M, Zhang Y (2015) Conduction heating of boron alloyed steel in application for hot stamping. Int J Precis Eng Manuf 16(9):1983–1992CrossRefGoogle Scholar
  19. 19.
    Mori K, Maeno T, Yamada H, Matsumoto H (2015) 1-shot hot stamping of ultra-high strength steel parts consisting of resistance heating, forming, shearing and die quenching. Int J Mach Tools Manuf 89:124–131CrossRefGoogle Scholar
  20. 20.
    Hayashi K (2006) Tool engineering for fineblanking and sheet metal forging complex work. Journal of the Japan Society for Technology of Plasticity 47(546):554–557 (in Japanese)Google Scholar
  21. 21.
    Yoon Y, Jeon H, Lee J (2013) Process design of cold forging with thick plate for seat recliner parts. Mater Des 49:449–455CrossRefGoogle Scholar
  22. 22.
    Merklein M, Lechler J (2006) Investigation of the thermo-mechanical properties of hot stamping steels. J Mater Process Technol 174(1–3):452–455CrossRefGoogle Scholar
  23. 23.
    Naderi M, Durrenberger L, Molinari A, Bleck W (2008) Constitutive relationships for 22MnB5 boron steel deformed isothermally at high temperatures. Mater Sci Eng A 478(1–2):130–139CrossRefGoogle Scholar
  24. 24.
    Mori K, Maeno T, Maruo Y (2012) Punching of small hole of die-quenched steel sheets using local resistance heating. CIRP Ann Manuf Technol 61(1):255–258CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London 2016

Authors and Affiliations

  • Ken-ichiro Mori
    • 1
  • Tomoyoshi Maeno
    • 2
  • Makoto Tsuchiya
    • 1
  • Tatsuhiro Nanya
    • 3
  1. 1.Department of Mechanical EngineeringToyohashi University of TechnologyToyohashiJapan
  2. 2.Division of Materials Science and Chemical Engineering, Faculty of EngineeringYokohama National UniversityYokohamaJapan
  3. 3.Toyota Boshoku CorporationToyotaJapan

Personalised recommendations