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

在TCRC73中，从根本上研究了轨道形成过程，展示了技术潜力。关于受控物质流动的可能性的工艺理解构成了本转让项目的基础。复杂程度高、工艺周期长是当今尚未解决的挑战。滚动板的系统特性决定了最大滚动角Θmax=1°的附加限制，这严重限制了成形能力。提交的转移方案的目的是用倾斜和转向迭代组合的方法取代传统的轨道成形过程。总体目标是通过使用适应的过程来扩展从基础研究中已知的过程限制。一方面，应该应用关于物质流动控制的基础研究的基本发现。另一方面，应提高工艺的成形性和效率。新工艺的一个基本优势是能够使用传统压力机，从而显著缩短了加工时间，并消除了Θ最大翻转角度=1°的限制。滚动角的增加提供了减少接触面积的潜力，从而实现了更大的成形能力。除了对倾斜过程进行分析外，还应评估实现所需形状填充所需的成形步骤数。此外，还必须评估最大倾角及其对功能部件的影响。为了提高承载能力，应分析强淬火高性能钢在成形过程中的硬化行为，以验证是否省略了后续的硬化过程。应通过综合工艺策略的研究和应用来优化目标参数。利用现有的轨道形成工艺设置，可以再现待研究的工艺特征，允许特征倾斜运动学。因此，可以从根本上研究新工艺，同时可以防止生产新工具概念的努力。因此，需要开发一种合适的方法来确保其适用性。由于修改后的工艺运动学会引起物流成分的预期变化，因此物流控制是必不可少的。采用数值模拟的方法对材料流动进行了分析。工艺参数对实际工艺的影响应通过对采用适应工艺生产的基准零件进行评估来研究。由于当前轨道成形工艺设置的上述缺点，调整后的工艺结果被转移到柔性工具概念中，用于常规压力机上。

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.