Increasing the range of producible geometries in open-die forging through superimposed stress states

通过叠加应力状态增加开式模锻可生产的几何形状范围

基本信息

批准号：
256896401
负责人：
Professor Dr.-Ing. Gerhard Hirt
金额：
--
依托单位：
Institut für Bildsame Formgebung (IBF)
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2014
资助国家：
德国
起止时间：
2013-12-31 至 2019-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/256896401?language=en
关键词：
Increasing range producible geometries open

项目摘要

Open-die forging is an incremental bulk forming process which is mainly used for the production of long and straight workpieces with a simple cross-section. The production of complex geometries by open-die forging usually requires additional manufacturing steps or can only be realized by a high amount of machining. Nevertheless, there is a certain demand for complex workpieces produced by open-die forging e.g. for aerospace applications or safety relevant parts.In other metal forming processes as for the production of curved extrusion or the process-integrated bending of tubes one approach to increase the range of producible geometries is the application of superimposed stresses in order to form the workpiece towards the intended geometry. This research project aims at the transfer of this concept to open-die forging to increase the range of producible geometries significantly.In the first funding period, the main focus was to generally prove the feasibility of the concept and analyze the technological potential. After analyzing the fundamental coherences for a single forming step, a kinematic concept for the production of curved workpieces in one forging pass was developed and successfully transferred to the open-die forging plant at the IBF. By this, it was possible to produce workpieces both from steel and aluminium with varying geometrical properties regarding the radius and workpiece angle which cannot be produced by conventional open-die forging. Additionally, the process-integrated torsion could be realized successfully.The second funding period aims at a further flexibilization of the concept regarding the achievable geometries and a detailed analysis of the process borders. For this purpose, in a first step the bending in vertical direction will be analyzed in detail, since this prevents the observed sliding of the workpiece between the forging dies and can be realized better on industrial open-die forging manipulators. A further increase of producible geometries shall be analyzed by investigating arbitrarily oriented bending direction in the 3D-space. Finally, the process borders will be analyzed in detail and concept will be evaluated, how the process can be optimized regarding these process borders for an industrial application of the concept.

开放式锻造是一个增量的体积形成过程，主要用于以简单的横截面生产长而直的工件。开放式锻造的复杂几何形状的生产通常需要额外的制造步骤，或者只能通过大量加工来实现。然而，开放式锻造产生的复杂工件有一定的需求，例如对于航空航天应用或安全性相关零件。在其他金属形成过程中，对于弯曲的挤出或试管的过程集成弯曲一种方法，以增加生产的几何形状的范围是叠加应力的应用，以形成工件朝向预期的几何形状。该研究项目的目的是转移该概念以大大增加生产的几何形状范围。在第一个资助期间，主要重点是通常证明该概念的可行性并分析技术潜力。在分析了单个形成步骤的基本相干之后，开发了一个用于生产曲面工件的运动学概念，并成功地转移到了IBF的开放式锻造工厂。这样，就可以从钢和铝中生产具有不同几何特性的钢和铝的工件，这些特性与传统的开放式锻造无法产生的半径和工件角度。此外，可以成功实现过程集成的扭转。第二个融资期旨在进一步灵活地将有关可实现的几何形状的概念和对过程边界进行详细分析。为此，将在第一步中详细分析垂直方向的弯曲，因为这可以防止观察到的锻造模具之间的工件滑动，并且可以在工业开放式锻造锻造机器上更好地实现。应通过研究3D空间中任意定向的弯曲方向来进一步增加生产几何形状。最后，将对过程边界进行详细分析，并将评估概念，如何在这些过程边界上优化该过程，以构成该概念的工业应用。