Measures for controlling the material flow when extruding sheet-bulk metal forming parts from coil

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Review Pub Date : 2020-01-01 DOI:10.1051/mfreview/2020033

J. Henneberg, M. Merklein

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Abstract

The increasing demand for lightweight design requires functional integration. This poses challenges to conventional manufacturing processes due to the rising geometrical complexity of components. The application of bulk forming operations to sheet metal, named sheet-bulk metal forming (SBMF), is one approach to overcome these challenges. Currently, mainly pre-cut blanks are applied in research of SBMF. Production from coil, in contrast, would combine the advantages of SBMF with the advantages of manufacturing from a coil regarding high output quantity. To research SBMF from coil, a lateral and a backward extrusion process are set up. In addition to a reduced geometrical accuracy of the parts, which is known from SBMF of pre-cut blanks, an anisotropic material flow is identified as a coil-specific challenge. The aim of this research is to investigate measures that extend the forming limits by means of a material flow control. For this purpose, a combined numerical-experimental approach is applied in order to analyze and evaluate an adaption of the width of the coil, the feed width, and the local friction as measures for material flow control. Particularly local adaptation of friction by means of modified tool surfaces reduces the anisotropic material flow and improves the geometrical accuracy of the parts.

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从卷材中挤出板材-大块金属成形件时控制物料流动的措施

对轻量化设计日益增长的需求要求功能集成。由于部件几何复杂性的增加，这对传统制造工艺提出了挑战。将大体积成形技术应用于金属薄板，称为薄板-大体积金属成形(SBMF)，是克服这些挑战的一种方法。目前，预切坯料主要应用于SBMF的研究。相比之下，线圈生产将结合SBMF的优势和线圈制造在高产量方面的优势。为了研究卷材的SBMF，建立了横向挤压和反向挤压工艺。除了从预切毛坯的SBMF可知的零件几何精度降低之外，各向异性材料流被认为是线圈特有的挑战。本研究的目的是研究通过材料流控制来延长成形极限的措施。为此，采用了数值-实验相结合的方法来分析和评估线圈宽度、进料宽度和局部摩擦作为物料流动控制措施的适应性。特别是通过修改刀具表面来局部适应摩擦，减少了材料流动的各向异性，提高了零件的几何精度。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Manufacturing Review ENGINEERING, MANUFACTURING-

CiteScore

5.40

自引率

12.00%

发文量

审稿时长

8 weeks

期刊介绍： The aim of the journal is to stimulate and record an international forum for disseminating knowledge on the advances, developments and applications of manufacturing engineering, technology and applied sciences with a focus on critical reviews of developments in manufacturing and emerging trends in this field. The journal intends to establish a specific focus on reviews of developments of key core topics and on the emerging technologies concerning manufacturing engineering, technology and applied sciences, the aim of which is to provide readers with rapid and easy access to definitive and authoritative knowledge and research-backed opinions on future developments. The scope includes, but is not limited to critical reviews and outstanding original research papers on the advances, developments and applications of: Materials for advanced manufacturing (Metals, Polymers, Glass, Ceramics, Composites, Nano-materials, etc.) and recycling, Material processing methods and technology (Machining, Forming/Shaping, Casting, Powder Metallurgy, Laser technology, Joining, etc.), Additive/rapid manufacturing methods and technology, Tooling and surface-engineering technology (fabrication, coating, heat treatment, etc.), Micro-manufacturing methods and technology, Nano-manufacturing methods and technology, Advanced metrology, instrumentation, quality assurance, testing and inspection, Mechatronics for manufacturing automation, Manufacturing machinery and manufacturing systems, Process chain integration and manufacturing platforms, Sustainable manufacturing and Life-cycle analysis, Industry case studies involving applications of the state-of-the-art manufacturing methods, technology and systems. Content will include invited reviews, original research articles, and invited special topic contributions.