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，这是因为冷锻生产的传统零件几何形状表现为旋转对称形状。因此，在本项目中，应开发一种新的剪切成形工艺，通过冷侧向挤压和剪切成形相结合的方式生产曲轴类零件。与常规的剪切成形和镦粗相结合的工艺相比，在轴伸缩部和凸缘的过渡区只有一个小的变形区。在该区域叠加了压应力，过程力和发生应力都减小了。这还会在凸缘区域造成较低的边缘圆角。为了研究几个工艺参数的影响，建议在本项目中设计和制造一种简单而模块化的工具。这样的工艺参数例如分别是侧向位移量或置换速度、反压力。本项目的主要目的是为工具直线运动的侧向挤压和剪切成形的组合成形过程提供基础和科学的知识。

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.