25-27 April 2022
Conventum Conference Center
Europe/Vienna timezone

Investigation on a quasi-incremental tool concept to manufacture functional components with sheet thickness gradient

27 Apr 2022, 11:20
Room 1

Room 1

Oral Presentation Tooling applications Tooling Applications


Andreas Hetzel (Institute of Manufacturing Technology, Friedrich-Alexander-Universität Erlangen-Nürnberg)


Global demands, like a reduction in carbon dioxide emissions and increased functional integration, require efficient forming operations and innovative process combinations in the manufacturing industry. One promising approach is the application of bulk forming operations on sheet metal in order to merge the advantages of both classes, defined as sheet-bulk metal forming. In this context, the process of orbital forming was investigated fundamentally and could be qualified for the manufacturing of functional components with a gradient in sheet thickness, like for example in a clutch system. Nevertheless, this tool setup disposes a lack in economic efficiency and is restricted by a maximum tumbling angle and a complex tool design. In this context, an innovative quasi-incremental process combination of tilting and turning is investigated with regard to the manufacturability of functional components with circumferential and cyclic symmetric material thickenings. The adapted tool concept is derived from conventional orbital forming and allows the intended linear tool movement by the simultaneous deflection of four hydraulic cylinders. Due to the adapted kinematics, the contact area between tool and workpiece increases from the center in a radial direction, resulting in a predominantly radial material flow. Since this new tool concept has not yet been investigated fundamentally, the aim within this research work is the establishment of a comprehensive process understanding of the forming parameters of this novel tool characteristic. Therefore, components out of the case-hardened steel C10 are manufactured and evaluated regarding the geometrical and mechanical properties. Different process strategies, like an increased forming force or a varying number of forming steps along different axis, are applied in order to optimize the forming behavior. The potential of the alternative tool setup to be used for the manufacturing of the components is pointed out by comparing the parts directly with conventionally orbital formed components.

Speaker Country Germany

Primary authors

Andreas Hetzel (Institute of Manufacturing Technology, Friedrich-Alexander-Universität Erlangen-Nürnberg) Dr Michael Lechner (Institute of Manufacturing Technology / Friedrich-Alexander-Universität Erlangen-Nürnberg) Prof. Marion Merklein (Institute of Manufacturing Technology / Friedrich-Alexander-Universität Erlangen-Nürnberg)

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