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Forming of Complex Functional Elements on Sheet Metal

  • Conference paper
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Sheet Bulk Metal Forming (TCRC73 2020)

Part of the book series: Lecture Notes in Production Engineering ((LNPE))

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Abstract

The rising demands on forming processes regarding the functional integration of components and lightweight construction pose a challenge to conventional processes. In that context, the application of bulk forming operations on sheet metal semi-finished products - also referred to as sheet-bulk metal forming (SBMF) - is a suitable approach to meet these challenges. One of the most relevant industrial forming processes is the cold extrusion, which enables a high material and energy efficiency. Furthermore, extruded components show beneficial mechanical properties, a high surface quality and can be produced with a near net-shape geometry. However, the application of cold forming processes for SBMF is limited due to an insufficient die filling and high tool loads. In order to meet these challenges and overcome resulting limitations, it is necessary to enhance the process understanding. This is achieved by establishing two different reference processes (forward and lateral extrusion) for the manufacturing of functional integrated geared components and the basic analysis of the occurring material flow and tool load in sheet-bulk metal forming processes. Through a combination of numerical and experimental analysis, similarities and differences between both processes are investigated. It is shown that design parameters, tribological conditions, as well as process parameters, substantially influence the process result, regarding achievable accuracy and tool load. The gained process understanding is used to identify limitations and to derive measures to expand the process boundaries.

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Acknowledgment

This project was supported by the German Research Foundation (DFG) within the scope of the Transregional Collaborative Research Centre 73 for sheet-bulk metal forming (TCRC 73, Subproject A2) under grant number TRR73/3 68237143. The authors are also grateful to all laboratory assistants and students who supported the execution of this work.

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Authors and Affiliations

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

    Manuel Reck, Andreas Rohrmoser, Andreas Jobst, Florian Pilz & Marion Merklein

Authors
  1. Manuel Reck
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  2. Andreas Rohrmoser
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  3. Andreas Jobst
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  4. Florian Pilz
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  5. Marion Merklein
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Corresponding author

Correspondence to Manuel Reck .

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Editors and Affiliations

  1. Lehrstuhl für Fertigungstechnologie, Friedrich-Alexander-Universität, Erlangen, Bayern, Germany

    Marion Merklein

  2. Institut für Umformtechnik & Leichtbau, Technische Universität Dortmund, Dortmund, Nordrhein-Westfalen, Germany

    A. Erman Tekkaya

  3. Institut für Umformtechnik und Umformmaschinen, Leibniz Universität Hannover, Garbsen, Niedersachsen, Germany

    Bernd-Arno Behrens

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Reck, M., Rohrmoser, A., Jobst, A., Pilz, F., Merklein, M. (2021). Forming of Complex Functional Elements on Sheet Metal. In: Merklein, M., Tekkaya, A.E., Behrens, BA. (eds) Sheet Bulk Metal Forming . TCRC73 2020. Lecture Notes in Production Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-61902-2_2

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  • DOI: https://doi.org/10.1007/978-3-030-61902-2_2

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  • Print ISBN: 978-3-030-61901-5

  • Online ISBN: 978-3-030-61902-2

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