Uniaxial hydroforming of cold forged cups on single action presses

金属成形工艺液压成形允许经济地制造主要用于汽车和供应商行业的两侧开口、底切和中空的轻质部件。典型的部件包括悬挂部件、排气和进气系统以及转向和驱动系统。该工艺基于加压流体介质将管子膨胀成模具形式。在本项目中，将常见的管材半成品液压成形过程的物理机理转移到单面开口冷锻半成品上。因此，本项目的总体目标是建立一个分析-经验过程模型，从根本上描述和解释单面开口冷锻零件在单动压力机上液压成形过程的因果关系。该工艺模型将有助于通过基于分析的工艺布局来实现高质量的、带有底切区域的冷锻件的制造。除了工艺开发和广泛的基本实验测试系列外，还打算用数值和分析工艺建模来描述、解释和预测未知的工艺极限，如断裂、屈曲和起皱，以及类似的工艺特有的不稳定性问题。

The metal forming process hydroforming allows an economical manufacturing of both sides opened, undercut, and hollow lightweight components that are mostly used in the automotive and supplier industry. Typical components are e.g. suspension parts, exhaust and intake systems as well as steering and drive systems. The process is based on the expanding of a tube into a die form by a pressurized fluid medium. In this project, the well-known physical mechanisms of the common hydroforming process of tubular semi-finished products are transferred to a single-side opened cold-forged semi-finished part. This results in extensively modified process conditions that need to be investigated.The overall goal of this project is therefore to establish an analytical-empirical process model that fundamentally describes and explains the cause-effect relationships of the hydroforming process of single-side opened cold-forged parts on single-action presses. This process model will help to realize the manufacturing of high quality, cold-forged components with undercut areas by an analytically-based process layout. In addition to the process development and a wide range of fundamental experimental test series the numerical and analytical process modelling to describe, explain and predict unknown process limits like rupture, buckling and wrinkling respectively similar process-specific instability problems is intended.