Functional Analysis of Components Manufactured by a Sheet-Bulk Metal Forming Process

Due to rising demands regarding the functionality and load-bearing capacity of functional components such as synchronizer rings in gear systems, conventional forming operations are reaching their limits with respect to formability and efficiency. One way to meet these challenges is the application of the innovative process class of sheet-bulk metal forming (SBMF). By applying bulk forming operations to sheet metal, the advantages of both process classes can be combined, thus realizing an optimized part weight and an adapted load-bearing capacity. Different approaches to manufacturing relevant part geometries were presented and evaluated regarding the process properties and applicability. In this contribution, a self-learning engineering workbench was used to provide geometry-based data regarding a novel component geometry with circumferential involute gearing manufactured in an SBMF process combination of deep drawing and upsetting. Within the comprehensive investigations, the mechanical and geometrical properties of the part were analyzed. Moreover, the manufactured components were compared regarding the increased fatigue strength in cyclic load tests. With the gained experimental and numerical data, the workbench was used for the first time to generate the desired component as a CAD model, as well as to derive design guidelines referring to the investigated properties and fatigue behavior.

[1]  S. Wernicke,et al.  Controlling material flow in incremental sheet-bulk metal Forming by thermal grading , 2020 .

[2]  D. Biermann,et al.  Influence of Tailored Surfaces and Superimposed-Oscillation on Sheet-Bulk Metal Forming Operations , 2020, Journal of Manufacturing and Materials Processing.

[3]  N. Dowling,et al.  Fatigue Crack Growth During Gross Plasticity and the J-Integral , 1976 .

[4]  B. Denkena,et al.  Analysis of Residual Stress States of Structured Surfaces Manufactured by High-Feed and Micromilling , 2015 .

[5]  Timothy W. Simpson,et al.  Metamodels for Computer-based Engineering Design: Survey and recommendations , 2001, Engineering with Computers.

[6]  J. P. Magrinho,et al.  Injection by sheet-bulk forming , 2019, Precision Engineering.

[7]  P. Bouchard,et al.  Damage in metal forming , 2020 .

[8]  H. Maier,et al.  Ductile Damage and Fatigue Behavior of Semi-Finished Tailored Blanks for Sheet-Bulk Metal Forming Processes , 2016, Journal of Materials Engineering and Performance.

[10]  Dieter Krause,et al.  New Approach for Lightweight Design: From Differential Design to Integration of Function , 2009 .

[11]  M. Lechner,et al.  Orbital Forming of Tailored Blanks for Industrial Application , 2020 .

[12]  Robert Schulte,et al.  Manufacturing of functional elements by sheet-bulk metal forming processes , 2016, Prod. Eng..

[13]  Eric R. Ziegel,et al.  The Elements of Statistical Learning , 2003, Technometrics.

[14]  Sebastian Götz,et al.  Betriebsfestigkeit , 2020 .

[15]  Sandro Wartzack,et al.  Simultaneous Development of a Self-learning Engineering Assistance System , 2021 .

[16]  Ken-ichiro Mori,et al.  State-of-the-art of plate forging in Japan , 2016, Prod. Eng..

[17]  Sandro Wartzack,et al.  SIMULATION-BASED DEVELOPMENT OF PARETO-OPTIMIZED TAILORED BLANKS FOR THE USE WITHIN SHEET-BULK METAL FORMING , 2016 .

[18]  P. Neumann,et al.  Life prediction for random load fatigue based on the growth behavior of microcracks , 1984 .

[19]  S. H. Goods,et al.  Overview No. 1: The nucleation of cavities by plastic deformation , 1979 .

[20]  Hossam A. Kishawy,et al.  Design for Sustainable Manufacturing: Approach, Implementation, and Assessment , 2018, Sustainability.

[21]  R. Kopp,et al.  Flexibly Rolled Sheet Metal and Its Use in Sheet Metal Forming , 2005 .

[22]  C. Wüthrich,et al.  The extension of the J-integral concept to fatigue cracks , 1982 .