Basic Investigations on Hollow Lateral Extrusion of Additional Shape Elements

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During the completed project phase, the hollow lateral extrusion of tubular semi-finished parts could be conducted for the first time and the fundamentals of this process for the production of near-net-shape and geometrically complex, hollow components could be developed. Here, the relations and influencing factors with particular regard to material flow were numerically and experimentally analyzed and process limits were determined. Additionally conducted investigations revealed the potential of a further process variant, the hollow lateral extrusion of hollow raw parts without utilization of lateral mandrels. The process shall allow the production of components with similar properties and, at the same time, ensure a significantly reduced tool complexity and increased process robustness. This process shall be investigated during the recent project phase. A fundamental objective is the development of tools and process control strategies for the production of near-net-shape components. A characteristic feature of this process variant is the only partial support of the workpiece by forming tools, which results in challenges regarding the control of the material flow. A novel process for the production of hollow flanges by lateral extrusion is a further innovative approach, which shall also be investigated. Hollow shafts, that can be produced by this process, shall be used as lightweight components with reduced mass moments of inertia in systems with moving masses, such as gear boxes.