Functional Analysis of Components Manufactured by a Sheet-Bulk Metal Forming Process

Due to rising demands regarding the functionality and load-bearing capacity of functional components such as synchronizer rings in gear systems, conventional forming operations are reaching their limits with respect to formability and efficiency. One way to meet these challenges is the application o...

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Bibliographic Details
Published inJournal of Manufacturing and Materials Processing Vol. 5; no. 2; p. 49
Main Authors Hetzel, Andreas, Schulte, Robert, Vogel, Manfred, Lechner, Michael, Besserer, Hans-Bernward, Maier, Hans Jürgen, Sauer, Christopher, Schleich, Benjamin, Wartzack, Sandro, Merklein, Marion
Format Journal Article
LanguageEnglish
Published Basel MDPI AG 01.06.2021
Subjects
Bearing capacity
Cyclic loads
Deep drawing
Engineering
fatigue life modeling
Fatigue strength
Fatigue tests
Functional analysis
functional behavior
Geometry
Load bearing components
Load tests
Manufacturing
Mechanical properties
Metal fatigue
Metal forming
Metal sheets
self-learning engineering workbench
sheet-bulk metal forming
Workbenches
Z-integral approach
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Summary:Due to rising demands regarding the functionality and load-bearing capacity of functional components such as synchronizer rings in gear systems, conventional forming operations are reaching their limits with respect to formability and efficiency. One way to meet these challenges is the application of the innovative process class of sheet-bulk metal forming (SBMF). By applying bulk forming operations to sheet metal, the advantages of both process classes can be combined, thus realizing an optimized part weight and an adapted load-bearing capacity. Different approaches to manufacturing relevant part geometries were presented and evaluated regarding the process properties and applicability. In this contribution, a self-learning engineering workbench was used to provide geometry-based data regarding a novel component geometry with circumferential involute gearing manufactured in an SBMF process combination of deep drawing and upsetting. Within the comprehensive investigations, the mechanical and geometrical properties of the part were analyzed. Moreover, the manufactured components were compared regarding the increased fatigue strength in cyclic load tests. With the gained experimental and numerical data, the workbench was used for the first time to generate the desired component as a CAD model, as well as to derive design guidelines referring to the investigated properties and fatigue behavior.
ISSN:2504-4494
2504-4494
DOI:10.3390/jmmp5020049