Potentials of dry rotary swaging

根据DIN 8583第3部分，旋锻属于开式模锻工艺。该技术广泛用于汽车行业的轻质部件生产，例如由管状坯料生产车轴和转向轴，从而为可持续和资源高效的生产技术做出贡献。另一方面，目前使用大量的矿物油基润滑剂，其实现了可靠工艺技术的重要任务。干式旋锻项目的上级目标是向干式加工转变，并显著改善工艺的资源平衡。为了实现这一目标，有必要分离润滑剂的当前功能，即机器和成形区的润滑，模具的冲洗和过程的冷却，并在每种情况下解决具体的新问题。由于任务的复杂性和多样性，所需的部分解决方案不能单独在一个学科中解决。在该项目中，来自成形技术，精密切削技术和表面技术领域的科学家必须合作。为了科普干式成型的挑战，我们打算将两种方法结合起来，即工具表面的结构化和涂层。结构化旨在包括几个尺度;涂层被实现为多层系统，以便在工具上的不同成形区域中产生优化的摩擦学条件。成功开发的技术将通过旋转旋锻试验来证明，这些试验使用的材料与工业应用高度相关。迄今为止的结果证实了所选择的途径和方法。

Rotary swaging belongs to the open die forging processes acc. to DIN 8583 part 3. The technology is widely used for the production of light weight components in the automotive industry, e.g. axle shafts and steering spindles from tubular blanks thus contributing to a sustainable and resource-efficient production technology. On the other hand large amounts of mineral oil based lubricant are currently used which fulfil important tasks for reliable process technology. Superior objective of the project dry rotary swaging is to change to dry processing and to improve the resource balance of the process significantly. To achieve the objective, it is necessary to separate the current functions of the lubricant, that means lubrication of machine and forming zone, flushing of dies and cooling of process, and to solve specifically new in each case. Due to the complexity and diversity of the task, the required partial solutions cannot be solved in one discipline alone. In the project, scientists from the field of forming technology, precision cutting technology and surface technology have to cooperate. To cope with the challenges of dry forming a combination of two approaches is intended, a structuring of the tool surface and a coating. The structuring is intended to comprise several scales; the coating is realized as a multilayer system in order to generate optimized tribological conditions in the different forming zones on the tool. The successfully development technology will be demonstrated by rotary swaging tests with materials which are of high relevance for industrial applications. The results so far confirm the chosen approaches and methods.