Process combination of lateral extrusion and shear forming with straight tool motion to manufacture crankshaft-like components

剪切成形工艺在冷锻领域并不常见，因为冷锻生产的传统部件几何形状显示出旋转对称的形状。因此，在这个项目中，应该开发一种新的剪切成形工艺，通过冷侧向挤压和剪切成形的结合来生产曲轴类部件。与传统的剪切成形和镦粗相结合的工艺相比，在轴伸和法兰的过渡区域只有很小的变形区。在这个区域，压应力叠加，过程力和发生应力都减小了。这还会在法兰区域造成较低边缘的圆角。为了研究几个工艺参数的影响，建议在这个项目中设计和制造一个简单的模块化工具。这样的工艺参数例如侧向位移量或位移速度分别为反压力。本课题的主要目的是为直刀运动下的侧向挤压与剪切复合成形工艺提供基础的科学知识。

Shear forming processes are not very common in the area of cold forging, due to the fact, that conventional component geometries produced by cold forging show a a rotationally symmetrical shape. Within this project, therefore, a novel shear forming processes should be developed to produce crankshaft-like components by a combination of cold lateral extrusion and shear forming. In contrast to the conventional process combination of shear forming and upsetting there is only a small deformation zone at the transition area of shaft extension and flange. In this area a compressive stress is superimposed and both the process forces and the occurring stresses are reduced. This additionally causes a lower edge rounding at the flange area. To investigate the impacts of several process parameters a simple and modular tool is suggested and should be designed and manufactured within this project. Such process parameters are for example the amount of lateral displacement or the displacement velocity respectively the counter pressure. The main project aim is to provide a basic and scientific knowledge for the combined forming process of lateral extrusion and shear forming with a straight tool motion.