Experimental and numerical investigations for the development of the Radial Rotation Profile-Forming

提出的研究项目的目的是开发径向旋转仿形(RRPF)制造技术。它的基本可行性和工艺特征基本原理是在第一个项目阶段开发出来的。在第二个项目阶段，重点是通过使用定制空白(TB)来扩展工艺限制。为此，定义了两个子目标：通过毛坯的局部不同的材料特性生产具有均匀材料预分配的预制件和通过不同的毛坯厚度生产具有恒定板厚的部件。到目前为止所进行的研究表明，旋转摆动折叠过程中的均匀起皱导致了形状均匀的型材，最终部件上的薄板厚度最小。这需要通过使用激光进行局部热处理来有针对性地控制旋转摆动折叠过程中的褶皱。激光加工的延长提供了这样的优点，即相对于总的加工持续时间，加工时间只发生了最小程度的延长。对于工艺链的延伸，将在拟议的研究项目范围内确定必要的特定材料和成形的相互关系，以实现对皱纹形成的最佳控制。结果表明，通过旋转摆动折叠，可以生产出各型面材料分布均匀的优化预制件，从而得到均匀的型材。对于第二个子目标，通过开发和应用可变板厚的薄板来优化最终零件上的板厚分布。除了生产具有恒定板厚的部件外，还考虑了具有载荷调整的板厚的部件的扭转刚度，以及重量优化的部件。在研究的范围内，探讨了TBS的使用以及与局部热处理相结合的几何刚度的变化所产生的影响。在研究范围内，通过数值模拟和实验研究，确定了整个工艺链上毛坯修形的工艺极限、影响参数和潜力。根据这些发现，得出了在轴向和切向上具有最佳板厚的异型空心构件的生产指南。

The aim of the proposed research project is the development of the RADIAL ROTATION PROFILING (RRPF) manufacturing technology. Its basic feasibility and process characteristic fundamentals were developed within the first project phase. In the second project phase, the focus is on extending the process limits by using Tailored Blanks (TB). To this end, two sub-objectives have been defined: the production of the preform with uniform material pre-distribution by locally different material properties of the blank and the production of components with constant sheet thickness by different sheet thickness of the blank. The investigations carried out so far show that uniform wrinkling during Rotational Swing-Folding leads to uniformly shaped profiles with minimum sheet thinning on the final component. This requires targeted control of wrinkling during Rotational Swing-Folding by local heat treatment using lasers. The extension by laser processing offers the advantage that, in relation to the total process duration, only a minimal extension of the process time takes place. For the extension of the process chain, the necessary material-specific and forming interrelationships will be worked out within the scope of the proposed research project in order to achieve optimum control of the wrinkle formation. As a result, an optimized preform withuniform material distribution in each profile of the die can be produced by Rotational Swing-Folding, which consequently results in a uniformly profiled component. For the second sub-objective, the sheetthickness distribution on the final part is optimized by developing and applying a TB with variable sheet thickness. In addition to the production of components with constant sheet thickness, components with load-adjusted sheet thickness are also considered with regard to torsional stiffness, as well as weight-optimized components. Within the scope of the investigations, the influences due to the use of TBs and the associated change in geometric stiffness in combination with local heat treatment are explored. Within the scope of the investigations, the process limits, influencing parameters and potentials of the blank modification on the entire process chain are identified by numerical and experimental investigations. The guidelines for the production of profiled hollow components with optimized sheet thickness in the axial and tangential directions are derived from these findings.