Analysis of Effectiveness of Locally Adapted Tribological Conditions for Improving Product Quality in Sheet-Bulk Metal Forming

Abstract

Due to current ecological and economic developments there is a growing demand for functional components with complex and closely tolerated geometrical features. Conventional sheet and bulk metal forming operations leads to products which are often limited in their geometrical and functional variety. A promising approach is the process-class sheet-bulk metal forming (SBMF). SBMF is characterised by the application of bulk and sheet forming operations on sheet metals [1]. This combination leads to locally and temporally varying load conditions regarding stress as well as strain states. In order to get high quality parts, controlling the material flow is of major importance. Modified Surfaces, so-called tailored surfaces represent an innovative approach to control the material flow. The objective of the current study is the experimental investigation of the effectiveness of locally adapted tribological conditions using workpiece-and tool-sided tailored surfaces within SBMF processes. The study has shown that the local adaption of workpiece and tool surface increased the heights of functional elements. Thus, using locally adapted tribological conditions leads to an improvement of the quality of the produced gearing components. In a further step the influence of surface modifications on the surface properties of the manufactured components are analysed. Additionally, investigations regarding the wear behaviour of tool-sided surface adaptions lead to the assumption, that the effectiveness of tailored surfaces is reduced during the operating time of the tools.