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A2 - Extrusion



Manufaction of Complex Extruded Functional Elements on Sheets

Project Status: Active

Last Update: 09.03.2017



Members


Subproject A2 directs towards the investigation of extrusion of functional elements. The overarching aim is to realize the manufacturing of geometrically challenging functional elements, such as synchronizer rings (fig. 1a). For this purpose, the fundamental forming of teeth at sheets in single-step extrusion processes was investigated in a first project phase (fig. 1b). As influencing factors for material flow during the forming process, the strain hardening of the material, the friction between material and tool and the geometrical flow restriction were identified. In line of a further increase of functional integration, the process of forming adjacent, geometrically different side elements, such as teeth- or driving-elements, was extended in project phase II (fig. 1c).a2 phasen tr eng

It has been shown that the influences identified in the first project phase, are affecting the forming of dissimilar functional elements, whereby the element geometry indirectly presents an influence factor as well. In particular, it was shown that the application of customized tailored blanks and tailored surfaces is improving the forming of functional elements. Part of the third phase is the arrangement of functional elements on different component radii, which is often necessary for functional integration of functional elements, such as on synchronizer rings (fig. 1d). Relevant challenges for the extrusion manufacturing are the functional forming of the form elements and the high tool loads, identified in phase II. In view of the mold filling, it will be audited if the material flow influences, identified in phase I and II, will take effect and if applicable how they will be used to control the material flow. To this, like in phase II, a forward- and cross-extrusion process based on simulation data will be designed. Variant simulations help to analyze relevant material flow influences and the derivation of possible process adaptation. In this context, an integration and further development of the tailored blanks and tailored surfaces take place, to reach a functional mold filling. Because of the high tool loads, identified in phase II, it requires a further development of the tool technology for a tool-failure-free forming of the components in view of the practice-relevant quantities. Because of the limited geometric design freedom of functional elements from compressive- as well as tensile strength of the used high performance tool steels in the second phase, a preload of the forming die aligned to the process is aimed. Because of the limited geometric design freedom of functional elements from compressive- as well as tensile strength of the used high performance tool steels in the second phase, a preload of the forming die aligned to the process is aspired. The integration of a local heat treatment in the tool manufacturing process should counteract the resulting brittleness in tool cavity with extra fatigue risk. With a suitable choice of parameters, a stress related increase of the toughness is aimed. The effectiveness of the approaches will be analyzed in laboratory tests and the transferability on practical conditions will be determined in a fatigue test stand. Wide knowledge for a systematical approach for the design of extrusion processes on sheets will exist at the end of the third phase. In addition, potentials and limits of manufacturing of functional elements on semi-finished sheets with forward- and lateral-extrusion will be identified and measures to increase of the process limits will be explored.

 


Working Groups


Publications

    2018

    • Pilz, F.; Gröbel, D.; Merklein, M.: Investigation of Fatigue Strength of Tool Steels in Sheet-Bulk Metal Forming. In: AIP Conference Proceedings 1960 (Edt.): The 21st International ESAFORM Conference on Material Forming, (2018)160022, AIP Publishing, pp. 1-6

    2017

    • Merklein, M.; Andreas, K.; Kraus, M.; Löffler, M.; Pilz, F.: Development and launching of an application-oriented test rig for wear investigations in sheet-bulk metal forming. In: THE"A" Coatings, (2017), Thessaloniki, GR, pp. 31-40

    2016

    • Merklein, M.; Lechner, M.; Gröbel, D.; Löffler, M.; Schneider, T.; Schulte, R.; Hildenbrand, P.: Innovative approaches for controlling the material flow in sheet-bulk metal forming processes. In: Manufacturing Review, 3(2016)2, pp. 1-17

    2015

    • Merklein, M.; Gröbel, D.; Löffler, M.; Schneider, T.; Hildenbrand, P.: Sheet-bulk metal forming – forming of functional components from sheet metals. In: Y. Qin, T.A. Dean, J. Lin, S.J. Yuan, F. Vollertsen (Edt.): Proceedings of the 4th International Conference on New Forming Technology, (2015), MATEC Web of Conferences, pp. 01001 1-12
    • Gröbel, D.; Schneider, T.; Merklein, M.: Sheet-Bulk Metal Forming. In: Tekkaya, A.E.; Homberg, W.; Brosius, A. (Edt.): 60 Excellent Inventions in Metal Forming, (2015), Springer, pp. 101-106
    • Gröbel, D.; Hildenbrand, P.; Engel, U.; Merklein, M.: Influence of tailored blanks on forming of cold forged functional elements in a sheet bulk metal forming process. In: Metec, Stahl-Institut VDEh (Edt.): Proceedings METEC & 2nd ESTAT, (2015), published on CD

    2014

    • Merklein, M.; Andreas, K.; Gröbel, D.; Hildenbrand, P.; Müller, M.; Noneder, J.; Reiß, A.; Schneider, T.; Vierzigmann, U.: Potenziale und Grenzen der Simulation in der Fertigungstechnik. In: Simufact Engineering (Edt.): Tagungsband 15. RoundTable - Simulating Manufacturing, (2014), Marburg: ISBN: 978-3-9813814-3-6, published
    • Gröbel, D.; Koch, J.; Vierzigmann, U.; Engel, U.; Merklein, M.: Investigations and approaches on material flow of non-uniform arranged cavities in sheet bulk metal forming processes. In: Procedia Engineering, 81(2014), pp. 401-406

    Presentations

      2018

      • 24.04.2018: Pilz, F.: Investigation of Fatigue Strength of Tool Steels in Sheet-Bulk Metal Forming, ESAFORM, Palermo, IT
      • 23.10.2018: Pilz, F.: Numerical Research of Sheet-Bulk Metal Forming Using a Forward and a Lateral Extrusion Process, ICFG Plenary Meeting 2018, Ohio, USA

      2017

      • 05.04.2017: Löffler, M.; Andreas, K.: Untersuchung des Werkzeugverschleißes in der Blechmassivumformung, GCFG Sitzung Stuttgart
      • 05.10.2017: Pilz, F.: Development and launching of an application-oriented test rig for wear investigations in sheet-bulk metal forming., Thessaloniki, GR