As part of the Collaborative Research Area Transregio 73 "Sheet Metal Forming", a new sheet metal forming process has been developed in the subproject A7 at the Institute for Forming Technology and Forming Machines. Its process limits were extended by introducing an oscillation superposition in the machine's main flow. The high contact stresses that occur during sheet metal forming lead to increased die wear, which are further researched on the basis of production trials. Cold forming and sheet metal forming processes as well of fischerwerke GmbH & Co. KG lead due to these very high contact stresses, to a significant die wear and high plant downtimes in the production. Since the die wear is currently difficult to realistically, the numerical wear calculation for full-forward extrusion and sheet metal forming processes is to be further developed in this project. Instead of the contact stresses, the numerical shaping of the wear should be implemented by means of the friction law (Shaw) and thus based on the friction shear stress. Furthermore, the influence of the forming temperature on the hardness of the dies should be considered with the calculation of the wear. By integrating vibration superposition into the process of full-forward extrusion, the surface quality of the components is to be improved and the friction is to be minimized. For this purpose, numerical as well as experimental investigations on a model process, which is derived from a complex multistage forming processes of the company fischer, can be realized.
In order to achieve the goals of the transfer project, a work program consisting of a total of six work packages will be set up. At the beginning of the research project, the workpiece material used is characterized by vibration-free and superimposed cylinder compression tests to determine the input parameters for the numerical simulation model.
In the next step, the numerical wear model for the forming process shall be developed and in collaboration with simufact engineering gmbh implemented into the simulation software. In parallel the demonstrative process will be designed and integrated into the existing die system with oscillating device. Subsequently, the experimental studies are carried out with and without vibration superimposition in order to transfer and analyze the advantages of the vibration superposition to the industrial process. On the basis of the obtained experimental data, the developed wear model is validated. After the model validation, parameter identification is used to determine optimal process parameters for the reduction of wear, which can be used for processes with high contact normal stresses, such as sheet metal and cold forming.
The project is within the transfer phase of the collaborative research area Transregio 73 "Sheet Metal Forming", supported by the “Deutsche Forschungsgemeinschaft (DFG)”.
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