TP6: High-speed blanking with electromagnetically accelerated tools for the production of functional surfaces at very high strain rates

该模型考虑了相关工艺参数对高速下料过程中产生的绝热剪切带（ASB）及其在大范围速度下的性能的影响。在TP6中，Fraunhofer IWU研究了最高的落料速度（≥10 m/s）和应变速率（高达10个5 - 5⁻¹）。这将允许在被冷落的表面产生非常窄的ASB，并在具有良好导热性的材料中启动ASB，将其用于生产技术并首次在材料科学方面对其进行表征。为了进行研究，IWU将开发并验证一个具有灵活应用的电磁加速冲床和广泛测量系统的试验台。电磁驱动器旨在将冲击器加速到10-25米/秒的最高速度。然后对for中使用的材料进行了全面的工艺分析。各种参数对冲裁过程和被冲裁表面性能的影响将被表征。为了利用互补的实验和数值方法对相互作用产生深刻的理解，影响因素（如撞击质量、速度）被仔细地彼此分离。在分析中，将整个过程分为电磁子系统和机械子系统。电磁分系统包括电感系统的电容放电、磁场和洛伦兹力的形成。机械子系统描述了冲击器和冲床的动力学、机械应力、工件的弹塑性变形以及最后的断裂。冲击器是两个子系统之间的连接。在电磁子系统的分析过程中，识别并量化了相关参数（如电感变型、电容器充电电压）对洛伦兹力和由此产生的冲击器运动的影响。在机械子系统的分析中，研究了刀具和工件的基本参数（如间隙、板材厚度）对工件断裂前的应力状态和变形的影响。在此基础上，研究了冲击器运动和应力状态对冲裁结果的影响。伴随着整个研究项目的数字支持的能源核算补充了技术调查。

The FOR considers the influences of relevant process parameters on the resulting adiabatic shear bands (ASB) and their properties over a wide range of speeds in high-speed blanking. In TP6, Fraunhofer IWU investigates the highest blanking speeds (≥10 m/s) and strain rates (up to 10⁵ s⁻¹). This shall allow to generate very narrow ASB in the blanked surfaces and to initiate ASB in materials with good thermal conductivity, exploit them for production technology and characterize them in terms of materials science for the first time. For the investigations, IWU will develop and validate a test rig with a flexibly applicable electromagnetically accelerated punch and extensive measurement systems. The electromagnetic drive is designed to accelerate an impactor to maximum speeds of 10–25 m/s. Then a comprehensive process analysis is performed for the materials used in the FOR. The influence of various parameters on the blanking process and the resulting blanked surface properties will be characterized. In order to create a deep understanding of the interactions using complementary experimental and numerical approaches, the influencing factors (e.g. impact mass, speed) are carefully separated from one another. In the analysis, the overall process is divided into an electromagnetic and a mechanical subsystem. The electromagnetic subsystem includes the capacitor discharge via the inductor system and the buildup of magnetic field and Lorentz force. The mechanical subsystem describes the dynamics of the impactor and punch, the mechanical stresses, the elasto-plastic deformation of the workpiece and finally the fracture. The impactor is the connection between the two subsystems. During the analysis of the electromagnetic subsystem, the influences of relevant parameters (e.g. inductor variants, capacitor charging voltage) on the Lorentz forces and the resulting impactor motion are identified and quantified. In the analysis of the mechanical subsystem, the influence of essential tool and workpiece parameters (e.g. clearance, sheet thickness) on the stress state and the deformation of the workpiece up to fracture is investigated. Based on this, the influence of impactor motion and stress state on the blanking result is investigated. The technological investigations are supplemented by a numerically supported energy accounting that accompanies the entire research project.