SUNConferences, COMA '13

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Manufacturing of Geared Sheet Metal Components by a Single-Stage Sheet-Bulk Metal Forming Process
Thomas Schneider, Marion Merklein

Last modified: 2013-08-20


Due to ecological and economic challenges particularly the automotive industry demands closely-tolerated complex functional components with variants. Regarding short process chains and improved mechanical properties current forming processes are often limited. A promising approach to fulfil these requirements is the combination of traditional sheet and bulk metal forming processes representing a new process-class named “sheet-bulk metal forming”, which is defined as forming of sheet metals out of the sheet plane with typical bulk forming operations, often combined with sheet forming operations. The challenge of applying conventional bulk forming operations on sheet metals is the interaction between regions of high and low strains and stresses, which is largely unknown.

To analyse this topic fundamentally, a single-stage process combination of deep drawing and upsetting is developed. Whereas a laminar body is formed by deep drawing with comparatively low tool load, variants in shape of gear teeth are upset at the pre-formed blank which results in high forming forces and contact pressures. The objective of this paper is the presentation of this new forming concept and both numerical and experimental investigations on the forming process. In the focus of interests is the identification of occurring process limits due to the material flow and the resulting mould filling behaviour. Therefore the effects of different process conditions regarding varying geometrical dimensions of the sheet metal specimen and tool components as well as the tribological system are analysed. Based on these results, the application of process adapted semi-finished products manufactured by forming processes is motivated and the potential for an enhancement of the detected process limits is shown.

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