Erarbeitung und Erprobung einer rechnergestützten Wissensbasis zur Vorhersage der Umformkräfte beim

FKM 1996 Issue No. 220 Project No. 191
Abstract:
Rotary swaging is a non-cutting, path-bound manufacturing process for reducing the cross-section of rod-shaped and tubular semi-finished products. The radial force required for this is applied directly to the circumference of the workpiece via oscillating tool segments. The forming process is particularly suitable for the production of rotationally symmetrical workpieces with stepped shell geometry. Against the background of the demand for lightweight construction, the process has recently become very interesting again. The weight saving is achieved by substituting workpieces made of solid material with round swaged tubular components. Although cold swaging has been known as a cold forging process for a long time, little research has been carried out into its basic principles. The investigations carried out as part of this project are primarily intended to serve the design and selection of rotary swaging machines on which workpieces with specified geometric and material-specific data are to be manufactured. This enables efficient, cost-effective and trouble-free production. As part of the test program, the curves and in particular the maximum values of the radial and axial forming forces were recorded. A measurement data acquisition system equipped with strain gauge sensors was available for this purpose, which even allowed individual impact analyses of the relatively high-frequency forming process with a sampling rate of up to 4000 Hz. As part of the experiments, the influences of all characteristic process parameters, such as axial and radial feed rate, radial infeed, axial travel, workpiece dimension and geometry, workpiece material, tool shape, etc. were investigated. In addition to the systematic evaluation of the large amount of data, this was entered into a database that is to serve as a knowledge base for machine selection. For this purpose, application-oriented database software was developed using the Visual Basic programming language. By specifying any parameters, this allows the test results to be determined whose boundary conditions largely match those of the workpiece to be produced. The forming forces resulting from the database, in particular their maximum values, then form the basis for selecting the rotary swaging machine to be used.


Scope of report:
130 pp., 117 illustrations, 11 tables, 39 references.

Start of work:
01.07.1994
End of work:
30.06.1996

Funding body:
AVIF/No. A 83

Research center:
Institute for Production Engineering and Forming Machines (PtU) at Darmstadt Technical University

Institute Director:
Prof. Dr.-Ing. D. Schmoeckel

Editor and author:
Dipl.-Ing. R. Gärtner

Chairman of the working group:
Dipl.-Ing. V. Keck, Mercedes-Benz AG

Chairman of the advisory board:
Prof. Dr.-Ing. H. Kipphan, Heidelberger Druckmaschinen AG