Potentials of dry rotary swaging

回转锻压属于开式模锻工艺。符合din8583第3部分。该技术被广泛用于汽车行业的轻量化部件的生产，例如用管状毛坯生产轴和转向轴，从而有助于实现可持续和资源节约型的生产技术。另一方面，目前大量使用矿物油为基础的润滑剂，以实现可靠的工艺技术的重要任务。该项目的主要目标是向干法加工转变，并显著改善该工艺的资源平衡。为了实现这一目标，有必要将润滑剂的现有功能分离开来，即机器和成型区域的润滑，模具的冲洗和过程的冷却，并在每种情况下具体解决新的问题。由于任务的复杂性和多样性，所需的部分解决方案不能单独在一个学科中解决。在该项目中，来自成形技术、精密切割技术和表面技术领域的科学家们必须进行合作。为了应对干燥成型的挑战，我们打算结合两种方法，即工具表面的结构和涂层。结构旨在包括几个尺度；为了在刀具的不同成形区域产生最佳的摩擦学条件，涂层被实现为一个多层系统。成功开发的技术将通过与工业应用高度相关的材料的旋转冲压试验来证明。到目前为止的结果证实了所选择的途径和方法。

Rotary swaging belongs to the open die forging processes acc. to DIN 8583 part 3. The technology is widely used for the production of light weight components in the automotive industry, e.g. axle shafts and steering spindles from tubular blanks thus contributing to a sustainable and resource-efficient production technology. On the other hand large amounts of mineral oil based lubricant are currently used which fulfil important tasks for reliable process technology. Superior objective of the project dry rotary swaging is to change to dry processing and to improve the resource balance of the process significantly. To achieve the objective, it is necessary to separate the current functions of the lubricant, that means lubrication of machine and forming zone, flushing of dies and cooling of process, and to solve specifically new in each case. Due to the complexity and diversity of the task, the required partial solutions cannot be solved in one discipline alone. In the project, scientists from the field of forming technology, precision cutting technology and surface technology have to cooperate. To cope with the challenges of dry forming a combination of two approaches is intended, a structuring of the tool surface and a coating. The structuring is intended to comprise several scales; the coating is realized as a multilayer system in order to generate optimized tribological conditions in the different forming zones on the tool. The successfully development technology will be demonstrated by rotary swaging tests with materials which are of high relevance for industrial applications. The results so far confirm the chosen approaches and methods.