Basic Investigations on Hollow Lateral Extrusion of Additional Shape Elements

在完成的项目阶段，可以首次进行管状半成品的中空侧向挤压，并可以开发该工艺的基本原理，以生产近净形状和几何复杂的中空部件。本文从数值和实验两方面分析了材料流动的关系和影响因素，并确定了工艺极限。此外，还进行了调查，揭示了另一种工艺变化的可能性，即在不使用侧向心轴的情况下对中空原材料进行中空侧向挤压。该工艺应允许生产具有类似性能的部件，同时确保显著降低工具复杂性和提高工艺稳健性。这一过程应在最近的项目阶段进行调查。一个基本目标是开发用于生产近净形状部件的工具和过程控制策略。该工艺变量的一个特点是仅通过成形工具对工件进行部分支撑，这导致了对材料流动控制的挑战。侧向挤压生产空心法兰的新工艺是一种进一步创新的方法，也应进行研究。在具有移动质量的系统中，可通过此工艺生产的空心轴应用作质量惯性矩减小的轻型部件，例如齿轮箱。

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.