Analysis of Horizontal Loads in Sheet-Bulk Metal Forming and Their Consideration in Simulation

authored by: Bernd Arno Behrens, Richard Krimm, Oliver Commichau
Abstract: Complex forming parts that include functional elements can be produced by means of sheet-bulk metal forming within one process step. Adding functional elements to a workpiece design can lead to design asymmetry. As a result, horizontal forces appear during the forming process, leading to horizontal displacements of the press ram. Such displacements lead to process inaccuracies. In this report, the appearance of press ram displacements is discussed. Studies were carried out to determine the amplitude of possible displacements. The impact of horizontal forces on the manufactured workpiece quality was investigated. A numerical study that featured both, the manufacturing process as well as a multibody-model of the press has been conducted to increase the accuracy of the process simulation. In order to avoid horizontal displacements of the press ram, electromagnetic solenoids were designed and built. Experiments were carried out that show the increased process accuracy by compensating press ram displacements by means of counteracting forces. Additionally, a reduction of tool wear by superimposing horizontal oscillations to the forming process was detected in an experimental approach. A concept for a tool, which adds the horizontal degrees of freedom to the framework of the press bed, is presented as well.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Contribution to book/anthology
Pages: 263-285
No. of pages: 23
Publication date: 2021
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Industrial and Manufacturing Engineering, Economics, Econometrics and Finance (miscellaneous), Safety, Risk, Reliability and Quality
Electronic version(s): https://doi.org/10.1007/978-3-030-61902-2_12 (Access: Closed)
: Details in the research portal "Research@Leibniz University"

BibTeX

@inbook{4a81745e65f549669cff45127bc9f0bd,
title = "Analysis of Horizontal Loads in Sheet-Bulk Metal Forming and Their Consideration in Simulation",
abstract = "Complex forming parts that include functional elements can be produced by means of sheet-bulk metal forming within one process step. Adding functional elements to a workpiece design can lead to design asymmetry. As a result, horizontal forces appear during the forming process, leading to horizontal displacements of the press ram. Such displacements lead to process inaccuracies. In this report, the appearance of press ram displacements is discussed. Studies were carried out to determine the amplitude of possible displacements. The impact of horizontal forces on the manufactured workpiece quality was investigated. A numerical study that featured both, the manufacturing process as well as a multibody-model of the press has been conducted to increase the accuracy of the process simulation. In order to avoid horizontal displacements of the press ram, electromagnetic solenoids were designed and built. Experiments were carried out that show the increased process accuracy by compensating press ram displacements by means of counteracting forces. Additionally, a reduction of tool wear by superimposing horizontal oscillations to the forming process was detected in an experimental approach. A concept for a tool, which adds the horizontal degrees of freedom to the framework of the press bed, is presented as well.",
author = "Behrens, {Bernd Arno} and Richard Krimm and Oliver Commichau",
note = "Funding Information: Acknowledgment. This study was supported by the German Research Foundation (DFG) within the scope of the Transregional Collaborative Research Centre for sheet-bulk metal forming (TCRC 73, Subproject B7) under grant number 68237143. The authors are in addition grateful to all laboratory assistants and students who supported the realization of this work.",
year = "2021",
doi = "10.1007/978-3-030-61902-2_12",
language = "English",
isbn = "978-3-030-61901-5",
series = "Lecture Notes in Production Engineering",
publisher = "Springer Nature",
pages = "263--285",
booktitle = "Lecture Notes in Production Engineering",
address = "United States",
}