Vergleichende Untersuchungen des Kraftbedarfs beim Kaltrundkneten mit unterschiedlichen Maschinenkon

FKM 2000
Booklet No. 254
Project No. 224

Abstract:

Rotary swaging is a chipless, path-bound manufacturing process for reducing the cross-section of bar and tube material. 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. The process has recently become more important, particularly due to the demand from the automotive industry for lightweight construction. A significant reduction in weight 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 done into its basic principles. Cold swaging is almost exclusively carried out using counter-stroke presses with cam gears, in external, internal and counter-rotating designs. Due to the different kinematics, it is currently not possible to transfer the process parameters from one machine type to another. The investigations carried out as part of this research project serve to design and select rotary swaging machines in order to ensure more efficient, cost-effective and trouble-free production. As part of the test program, the process forces, i.e. radial and axial components, were recorded with specific variation of the process parameters. For this purpose, an external rotor machine and a counter-rotating machine were available, which were equipped with suitable measuring sensors. In the experiments, the influences of characteristic process parameters such as machine type, axial and radial feed rate, semi-finished product dimensions, material, swaging frequency, rotary feed rate and lubrication condition were investigated. The experimental results were then integrated into an existing technology database (result of the A VIF project A83). Furthermore, applications such as the integrated calculation module for estimating the force requirement for data that is not exactly available in the database were implemented in the database software. This has significantly extended the range of possible applications. In addition, parameters such as drive shaft speeds, lubrication condition and machine designation have been integrated into the search algorithm. To optimize the user interface, the user has been provided with online help and a print function. The results achieved within the scope of the project now provide the user with database software to design rotary swaging processes more easily and efficiently. 139 p., 132 ill., 5 tab., 32 lit. 01.10.1997 30.09.1999 AviF/No. A 124 Institute for Production Technology and Forming Machines (ptU) of the Technical University of Darmstadt, Institute Director:
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche Dipl.-Ing. F. Heislitt Dipl.-Ing. V. Keck, DaimlerChrysler AG Dipl.-Ing. Jürgen Rabe, Sachsenring Autobiltechnik AG, Zwickau