Investigations on Orbital Forming of Sheet Metals to Manufacture Tailored Blanks with a Defined Sheet Thickness Variation

Abstract:

Orbital forming is an incremental bulk cold forming process with many advantages. It can produce net-shape or near-net-shape parts that have superior mechanical properties due to work hardening compared to manufacturing with cutting processes or hot forming. In this work the orbital forming process is employed in a closed-die configuration. A rising of the material thickness in the outer areas of a circular sheetmetal blank is enabled by preventing the lateral material flow. The main effects and subsequently the effects of the interaction of parameters were investigated by a two-step design of experiments. A screening plan was used to identify the statistically relevant parameters. The effects were then studied in a subsequent central-composite design of experiments. With the measured data a nonlinear response-surface model was parameterized to describe the dependency of the mould filling on the investigated process parameters. This model was validated experimentally and showed a good agreement to reality. Additionally a new concept for the tool system was developed and investigated. The form-defining cavity can be changed from the upper punch to the counterpunch.

• Periodical: Advanced Materials Research (Volume 769)
• Pages: 157-164
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.769.157
• Online since: September 2013
• Authors: Raoul Plettke, Simon Opel
• Keywords: Cold Forming, Orbital Forming, Steel

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