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A1 - Deep Drawing (funding period 1)



Process combination for manufacturing of teethed, thin-walled functional components out of tailored blanks

Project Status: finished

Last Update: 02.07.2012



Members


The focus of the project is on the setup and fundamental scientific analysis of a process combination suited for manufacturing of teethed, thin-walled functional components using tailored blanks by metal forming. In consequence of the trend towards shortened process chains, a tool concept which integrates a deep drawing und upsetting operation in a single forming stage was developed. Based on numerical results high loads on tool and workpiece had to be taken into account to achieve an adequate mould filling. To enhance the forming limits of this process combination concerning part quality, the use of tailored blanks with selected thickness characteristic was investigated and approved in FE-simulation. In the later course of the project, the numerical results have to be verified by an experimental setup as well as the potential of semi-finished products made by a flexible rolling process has to be shown.

Integrated deep drawing and upsetting tool (left) and intermediate shapes of the component (right)

Manufacturing of complex sheet metal components containing functional elements can be enabled by the application of bulk forming operations on planar semi-finished products. Considering a large contact area the forming process requires innovative concepts to reduce the forming forces. Within the subproject the manufacturing of process adapted tailored blanks with a defined sheet thickness characteristic and locally adapted mechanical properties is investigated. The applied forming processes are upsetting and flexible rolling. Aim of the project is the setup and fundamental scien-tific analysis of both forming processes. The prototypic rolling machine with a flexible process strategy enables the realisation of various blank layouts, designing the semi-finished products for successive forming operations.

Flexible rolling machine and numerical investigations of the rolling process


Working Groups


Publications

    2020

    • Vogel, M.; Schulte, R.; Hetzel, A.; Lechner, M.; Merklein, M.: Verfahrenskombination zur umformtechnischen Herstellung von verzahnten, dünnwandigen Funktionselementen aus prozessoptimierten Halbzeugen. In: Bernd-Arno Behrens (Edt.): Aktuelle Entwicklungen im Bereich der Umformtechnik - 23. Umformtechnisches Kolloquium Hannover 04. und 05. März 2020, (2020), Hannover: TEWISS, pp. 178

    2019

    • Hetzel, A.; Schulte, R.; Degner, J.; Merklein, M.: Maßgeschneiderte Halbzeuge - Umformtechnische Herstellung von Funktionsbauteilen zur Realisierung von Leichtbaukomponenten109(2019)10, Werkstattstechnik online, pp. 745-749

    2016

    • Löffler, M.; , .; Engel, U.; Schulte, R.; Gröbel, D.; Krebs, E.; Freiburg, D.; Biermann, D.; Stangier, D.; Tillmann, W.; Weikert, T.; Wartzack, S.; Tremmel, S.; Lucas, H.; Denkena, B.; Merklein, M.: Tribological measures for controlling material flow in sheet-bulk metal forming. In: Production Engineering, (2016), accepted
    • 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

    • 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

    2012

    • Merklein, M.; Plettke, R.; Schneider, T.; Opel, S.: Manufacturing of sheet metal components with variants using process adapted semi-finished products. In: Key Engineering Materials, 504(2012), Schweiz: Trans Tech Publications, pp. 1023-1028
    • Weckenmann, A.; Reithmeier, E.; Merklein, M.; Wartzack, S.; Behrens, B.; Akkasoglu, G.; Ohrt, C.; Schneider, T.; Salfeld, V.; Breitsprecher, T.; Plugge, B.: Methodengestützte Referenzvorgehensweise für neue Umformverfahren. In: Zeitschrift für wirtschaftlichen Fabrikbetrieb ZWF, 107(2012)1, München: Hanser, pp. 43-47
    • Merklein, M.; Plettke, R.; Opel, S.: Orbital forming of tailored blanks from sheet metal. In: Annals of the CIRP, 1(2012)61, Amsterdam: Elsevier, pp. 263-266

    2011

    • Merklein, M.; Schneider, T.: Functional Integration of Sheet Metal Parts by Deep Drawing(2011), Steel Research International - Special Edition ICTP 2011, pp. 1036-1041
    • Schneider, T.; Merklein, M.: Sheet-Bulk Metal Forming of Preformed Sheet Metal Parts(2011), Schweiz, pp. 83-90
    • Merklein, M.; Tekkaya, A.; Brosius, A.; Opel, S.; Kwiatkowski, L.; Plugge, B.; Schunck, S.: Machines and Tools for Sheet-Bulk Metal Forming. In: Key Engineering Materials, 473(2011), Schweiz: Trans Tech Publications, pp. 91-98
    • Merklein, M.; Koch, J.; Opel, S.; Schneider, T.: Fundamental investigations on the material flow at combined sheet and bulk metal forming processes. In: Annals of the CIRP, 1(2011)60, Amsterdam: Elsevier, pp. 283-286
    • Merklein, M.; Tekkaya, A.; Brosius, A.; Opel, S.; Koch, J.: Overview on Sheet-Bulk Metal Forming Processes. In: G. Hirt, A.E. Tekkaya (Edt.): Proceedings ICTP 2011, 10(2011), Aachen, pp. 1109-1114
    • Merklein, M.; Behrens, B.; Plettke, R.; Krimm, R.; Opel, S.; Schneider, T.; Salfeld, V.: Integrierte Fertigung von tiefgezogenen Blechbauteilen mit Verzahnungselementen unter Einsatz von prozessangepassten Halbzeugen. In: M. Merklein (Edt.): Tagungsband zum 1. Erlanger Workshop Blechmassivumformung 2011, (2011), Bamberg: Meisenbach, pp. 159-180
    • Schaper, M.; Lizunkova, Y.; Vucetic, M.; Hetzner, H.; Opel, S.; Schneider, T.; Koch, J.; Plugge, B.: Sheet-bulk metal forming a new process for the production of sheet metal parts with functional components. In: Metallurgical and Mining Industry, 3(2011)7, pp. 53-58

    2010

    • Merklein, M.; Opel, S.; Schneider, T.: Herstellung funktionaler Blechkomponenten. In: wt Werkstattstechnik online, 11(2010), Düsseldorf: Springer, pp. 910-915
    • Merklein, M.; Opel, S.: Investigation of Tailored Blank Production by the New Process Class Sheet-Bulk Metal Forming . In: F. Chinesta, Y. Chastel, M.E. Mansori (Edt.): International Conference on Advances in Materials and Processing Technologies (AMPT2010), 1315(2010), Melville, USA: AIP Conference Proceedings, pp. 395-400
    • Merklein, M.; Koch, J.; Schneider, T.; Opel, S.; Vierzigmann, U.: Manufacturing of Complex Functional Components with Variants by Using a new Metal Forming Process – Sheet-Bulk Metal Forming. In: International Journal of Metrial Forming, (2010), Paris: Springer, pp. 347-350

    2009

    • Merklein, M.: Manufacturing of complex functional components with variants by using a new sheet metal forming process. In: Ruan, X.-Y. (Hrsg.): Proc. of 42nd ICFG Plenary Meeting(2009), published

    Presentations

      2012

      • 15.03.2012: Opel, S.: Manufacturing of sheet metal components with variants using process adapted semi-finished products, Erlangen

      2011

      • 18.04.2011: Opel, S.: Machines and Tools for Sheet-Bulk Metal Forming, Leuven
      • 18.04.2011: Opel, S.: Sheet-Bulk Metal Forming of Preformed Sheet Metal Parts, Leuven
      • 28.09.2011: Schneider, T.: Functional Integration of Sheet Metal Parts by Deep Drawing, ICTP, Aachen
      • 13.10.2011: Plettke, R.: Integrierte Fertigung von tiefgezogenen Blechbauteilen mit Verzahnungselementen unter Einsatz von prozessangepassten Halbzeugen, 1. Workshop Blechmassivumformung, Erlangen, Germany

      2010

      • 09.04.2010: Schneider, T.: Manufacturing of Complex Functional Components with Variants by Using a New Metal Forming Process – Sheet-Bulk Metal Forming, ESAFORM 2010, Brescia
      • 25.10.2010: Opel, S.: Investigation of Tailored Blank Production by the Process Class Sheet-Bulk Metal Forming, Paris