Development of a manufacturing process for functional components with a varying sheet thickness profile (T10#)

开发具有不同板材厚度轮廓的功能部件的制造工艺（T10

• 批准号: 457204991
• 金额: --
• 依托单位: Lehrstuhl für Fertigungstechnologie (LFT)
• 依托单位国家: 德国
• 项目类别: CRC/Transregios (Transfer Project)
• 财政年份: 2021
• 资助国家: 德国
• 起止时间: 2020-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/457204991?language=en
• 关键词: Development; manufacturing; process; functional; components

Within the TCRC 73, the process of orbital forming was investigated fundamentally and the technolog-ical potential was shown. The process understanding referring to the possibility of controlled material flow forms the basis for the present transfer project. A high complexity as well as a long process dura-tion are unsolved challenges today. The system specific dependency of a tumbling plate results in an additional restriction of a maximum tumbling angle of Θmax = 1°, which severely limits the forming ca-pacity.The aim of the submitted transfer project is the substitution of the conventional orbital forming process by an iterative combination of tilting and turning. The overall objective is to extend the process limits known from fundamental research by using an adapted process. On the one hand, the essential find-ings of fundamental research regarding the control of the material flow should be applied. On the other hand, the formability and efficiency of the process should be improved. A basic advantage of the new process is the ability to use a conventional press, thus significantly reducing the process time and removing the restriction of a maximum tumbling angle of Θmax = 1°. An increase of the tumbling angle offers the potential of a reduced contact area, realizing an increased forming capacity.Challenges of the innovative manufacturing process can be derived from the modified process charac-teristics and forming kinematics. Besides the analysis of the tilting process, the number of forming steps required to achieve the desired form filling should be evaluated. In addition, the maximum tilt angle and the resulting influence on the functional components must be evaluated. In order to in-crease the load capacity, the hardening behaviour of strongly hardened high performance steels dur-ing the forming process should be analysed to verify the omission of a subsequent hardening process. The target parameters should be optimized by an investigation and application of comprehensive pro-cess strategies.The process characteristics to be investigated can be reproduced by using the current orbital forming process setup, allowing the characteristic tilting kinematic. Thus, the new process can be investigated fundamentally and at the same time, the effort for the production of the new tool concept can be pre-vented. Therefore, the development of a suitable method to ensure the applicability is required. Due to the expected change of the material flow components caused by the modified process kinematics, a material flow control is essential. A numerical simulation is used for the analysis of the material flow. The influence of the process parameters on the actual process should be investigated by evaluating reference parts produced with the adapted process. Due to the mentioned disadvantages of the cur-rent orbital forming process setup, the results of the adapted process transferred to a flexible tool con-cept for the use on a conventional press.

在TCRC 73中，从根本上研究了轨道形成的过程，并显示了技术潜力。过程理解指的是控制物料流的可能性，这构成了当前转移项目的基础。高复杂性和长过程持续时间是目前尚未解决的挑战。翻滚板的系统特定依赖性导致最大翻滚角Θmax = 1°的附加限制，这严重限制了成形能力。提交的转移项目的目的是用倾斜和转向的迭代组合取代传统的轨道形成过程。总体目标是通过使用适应性过程来扩展从基础研究中已知的过程限制。一方面，应该应用有关物料流控制的基础研究的重要发现。另一方面，该工艺的成形性和效率也有待提高。新工艺的一个基本优势是能够使用传统的压力机，从而大大减少了工艺时间，并消除了Θmax = 1°的最大翻滚角的限制。增加翻滚角提供了减少接触面积的潜力，实现了增加的成形能力。创新制造工艺的挑战可以从工艺特性和成形运动学的修改中得到。除了分析倾斜过程外，还应评估实现所需表单填充所需的成形步骤的数量。此外，必须评估最大倾斜角及其对功能部件的影响。为了提高承载能力，应分析强硬化高性能钢在成形过程中的硬化行为，以验证后续硬化过程的遗漏。通过综合工艺策略的研究和应用，对目标参数进行优化。所要研究的过程特征可以通过使用当前的轨道成形过程设置来重现，允许特征倾斜运动学。因此，可以从根本上研究新工艺，同时可以防止新刀具概念生产的努力。因此，需要开发一种合适的方法来保证其适用性。由于改进的工艺运动学所引起的物料流分量的预期变化，物料流控制是必不可少的。采用数值模拟方法对物料流动进行了分析。工艺参数对实际工艺的影响应通过评价采用适应工艺生产的参考零件来研究。由于目前轨道成形工艺设置的上述缺点，适应过程的结果转移到一个灵活的工具概念上使用的传统压力机。