Incremental high speed forming processes

由于工具的几何限制，使用传统的成形程序（如多级深拉深）几乎不可能经济地制造具有不同变化且小批量的复杂零件。即使是微小的几何变化也需要昂贵的措施来调整现有的工具或生产新的工具。该项目旨在开发创新的柔性制造工艺以及适用于广泛应用的合适工具技术。具体而言，基于高脉冲电流的高速金属成形工艺：电液成形（EHF）和电磁成形（EMF）将通过对上述操作集成增量方法，分别发展为电液增量成形（EHIF）和电磁增量成形（EMIF）。这就结合了高速和增量金属成形的优势，使得在满足几何和尺寸要求的同时，能够灵活地调整小批量不同变化的复杂零件的制造。为此，将对选定的材料进行增量高速金属成形的数值分析和实验分析。这里的重点是铝合金ena6016和ena1050。为了研究该工艺在其他材料上应用的可能性，对铜合金Cu-DHP、钢DC04和不锈钢1.4301进行了试验。计划分析的目的一方面是确定机床、刀具、工艺和工件参数之间的相互关系，另一方面是确定所生产零件在几何形状、精度和表面质量方面达到所需质量要求的可能性，以及材料的硬化特性。数值分析的目的是初步设计实验所需的工具，并研究在这项工作的后期很难或不可能通过测量技术获得的工艺参数。实验部分的目的是验证数值分析，除了分析成形过程的各个方面，有助于减少不必要的数值模拟工作和成本。

The economical manufacturing of complex parts with different variations and yet small lot sizes is almost impossible using conventional forming procedures like in multi-stage deep drawing due to the geometrical limitations of the tools. Even minor geometrical changes require expensive measures of adjusting existing tools or producing new ones. The proposed project yields to develop innovative flexible manufacturing processes along with a suitable tooling technology for a wide spectrum of applications. Specifically, high-speed metal forming processes based on high impulse current: electrohydraulic forming (EHF) and electromagnetic forming (EMF) will be developed into electrohydraulic incremental forming (EHIF) and electromagnetic incremental forming (EMIF) re-spectively by integrating an incremental approach to the mentioned operations.This results in combining the advantages of high speed and incremental metal forming which enables flexible adjustments for the manufacturing of complex parts with different variations in small lot sizes while complying to the geometrical and dimensional requirements. For this purpose numerical in addition to experimental analysis on incremental high-speed metal forming will be carried out on selected materials. Here the emphasis is on Aluminum alloy EN AW 6016 and EN AW 1050. For studying the possibility of applying the proposed process on other materials, copper alloy Cu-DHP, steel DC04 and stainless steel 1.4301 are examined. The planned analysis aim to determine the interrelations between the machine, tools, process and workpiece parameters on one hand, and the possibility of achieving the required quality requirements of the produced part in terms of geometry, accuracy and surface quality in addition to the hardening characteristics of the materials on the other hand. The numerical analysis aim to design the required tools for experiments initially, in addition to study process parameters that are hard or impossible to obtain through measurement technology in advanced stages of this work. The experimental part has the objective of validating the numerical analysis, in addition to analyzing aspects of the forming process that help in minimizing unnecessary numerical simulation effort and costs.