Wear prediction and characterisation of load-adjusted profiles with secondary design elements within draw bending

第一个研究阶段的研究表明，拉伸弯曲与综合热处理的可行性，以生产负载适应型材部件。下一学期的目的是研究与二次成形元件生产可变轮廓截面几何形状有关的拉伸弯曲过程。二次设计元素的应用增加了型材的刚度，从而增加了它们的应用范围。此外，生产可变截面和局部热处理的可能性使得生产具有定制性能的部件成为可能。为此，需要利用数值模拟开发和分析毛坯的优化几何形状。此外，还计划在第二个应用阶段对拉伸弯曲机进行改进，以便生产复杂的几何形状。对于后续的工业实施，摩擦学接触条件和磨损行为的基础研究是至关重要的。预计会增加磨损，特别是在热成形过程中二次成形元件的情况下。除了技术和科学方面的挑战外，还将获得有关综合热处理拉拔弯曲过程中刀具磨损的详细知识。在第一阶段实验结果的基础上，建立了拉拔弯曲过程的刀具磨损模型。刀具磨损必须定义为工艺特定接触压力、相对速度以及与温度相关的刀具硬度的函数，并将在有限元系统中实现。将对模拟磨损预测进行验证，并用于预估拉弯刀具的刀具寿命。

The investigations of the first research period have shown the feasibility of draw bending with integrated heat treatment for the production of load-adapted profile components. The following term aims to investigate the draw bending process regarding the production of variable profile cross-sectional geometries with secondary forming elements. The stiffness of the profiles and thus their application range is to be increased by the application of the secondary design elements. Moreover, the possibility to produce variable profile cross sections and a partial heat treatment makes it possible to produce components with tailored properties. For this purpose, an optimized geometry of the blank is to be developed and analyzed using numerical simulations. In addition, an enhancement of the draw bending machine is also planned for the second application period which will allow the production of complex geometries.For the subsequent industrial implementation, fundamental investigations on tribological contact conditions and wear behavior are of vital importance. An increased wear is expected, particularly in the case of secondary forming elements during hot-forming processes. In addition to the technological and scientific challenges, detailed knowledge about the tool wear during draw bending with integrated heat treatment will be obtained. Based on the experimental results of the first research period, a tool wear model for the draw bending process will be developed. The tool wear has to be defined as a function of the process specific contact pressure, the relative velocities as well as the temperature dependent tool hardness and will be implemented in an FE system. The simulative wear prediction will be validated and used to estimate the tool life of the draw bending tools.