Friction-Spinning – an Innovative Incremental Forming Process for the Manufacturing of Functional Graded Parts

Abstract:

Friction spinning is an innovative incremental forming process for the manufacture of tailor-made components with defined functionally graded properties. The process is characterized by the use of friction sub-processes for self-induced heat generation that can be employed for the defined thermo-mechanical treatment. Due to this in-process heat treatment, it is possible to extend the forming limits and achieve more complex geometries as well as favorable part properties. One very interesting application for friction spinning is the sealing of tube ends. There are a lot of conceivable application fields, including the substitution of soldering or welding operations in chemical engineering. Another interesting field is the use of this incremental forming process for industrial or automotive applications such as the manufacture of very slim cylindrical cups. An advantage of this method is the feasibility of defined control of the thickness distribution in the bottom and side wall area. This is supported by a new tool system with a pivoting forming tool. The pivot movement is controlled by a process control system. This system makes it possible to achieve different contact conditions between the tool and the workpiece during the process so as to attain a defined influence on the material flow and hence to enhance the attainable bottom wall thickness compared with previous fixed-angle tools. This tool concept thus offers an opportunity to improve the properties of the components as well as to manufacture new and complex geometries, such as hollow, fully closed roll type parts.

• Periodical: Key Engineering Materials (Volumes 554-557)
• Pages: 1368-1374
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.554-557.1368
• Online since: June 2013
• Authors: Werner Homberg, Benjamin Lossen, A. Struwe
• Keywords: Friction Spinning, Incremental Sheet Forming (ISF), Process Design, Tool System, Tube

References

[1] Kleiner, M.; Geiger, M.; Klaus, A., 2004, Manufacturing of Lightweight Components by Metal Forming, Annals of the CIRP, Vol. 52/2/2003, S. 521-542

DOI: 10.1016/s0007-8506(07)60202-9

[2] Finckenstein, E. von, Dierig, H., 1990, CNC-Drücken, Annals of the CIRP, Vol. 39/1: 267-270

DOI: 10.1016/s0007-8506(07)61050-6

[3] Neugebauer, R., Altan, T., Geiger, M., Kleiner, M. and Sterzing, A., Sheet Metal Forming at Elevated Temperatures, Annals of the CIRP 55/2 (2006), p.793–816

DOI: 10.1016/j.cirp.2006.10.008

[4] Awiszus, B.; Meyer, F.; Meyer, L.W.; Hahn, F.: Erweiterung der Formgebungsgrenzen durch inkrementelle zyklische Umformung am Beispiel des Drückwalzens (Abstreckdrücken). Tagungsband zum Abschlusskolloquium des DFG Schwerpunktprogramms 1074 "Erweiterung der Formgebungsgrenzen bei Umformprozessen", 3. Mai 2005, Aachen, (2005)

[5] Homberg, W.; Hornjak, D., 2011: Friction-Spinning of Tubular Components - Basic Research on Parameter Influence and Process Design; ITCP 2011, Aachen, Germany

[6] Homberg W., Lossen B.: Reib-Drücken – ein innovativer Ansatz zur effizienten Herstellung von funktional gradierten Bauteilen aus Aluminium- und Stahlwerkstoffen - 1. Pforzheimer Werkstofftag 2012, 12. September 2012, Pforzheim, Deutschland

DOI: 10.37544/1436-4980-2009-10-728

[7] Homberg W., Hornjak D., Lossen B., Struwe A.: New Innovative Tool Systems for the Production of Workpieces with Tailor-made Properties by Friction Spinning; Metal Forming - 14th International Conference, 16. – 19. September 2012, Krakau, Polen

DOI: 10.1063/1.3589511