P 892 – Determination and optimization of the process influencing material-specific parameters for the sheet metal extrusion process of high strength steels
One of the goals of this research project therefore was to find process parameters and influencing factors as e.g. material properties for regular and high-strength materials through experiments and simulation that will allow optimizing the production process for higherstrength materials and increasing its reliability in an industrial environment. In order to gain a more thorough knowledge of the factors influencing the extrusion process, systematic and scientifically based experimental and numerical experiments were run. The first experiments of the extrusion process focused on circular geometries when using regular steel blanks. By trying to reproduce the metal forming process as accurately as possible on a digital model, it was possible to gain insight into the occurring forces during the usage of the tool. These experiments were also used to validate the created simulation model. Based on the knowledge gained from the experiments and the simulation, the used circular and the gear geometry were optimized. The goal behind this effort was to increasethe endurance of the die by adding a chamferradiuscombination to the outer shell surface. In addition to this, further research regarding the material’s hardening, the occurring forces, and the geometries’ influence as a function of the material used, the die clearance, the flange’s radius, and the preparation of the shell surface. Using both, the results from the experiments as well as the simulation, it was possible to establish borderlines for the feasibility of the sheet metal extrusion process.
The improved control of all relevant parameters during the sheet metal extrusion process allows to significantly reduce the manufacturing cost for high-strength steels whilst further improving the process stability. This study also allowed to identify the technical limitations of the current process and subsequently lead to the development of new tool construction guidelines which allow for a quick and practical application of the developed procedure.
The research project (IGF-Nr. 17103 N) was carried out at Lehrstuhl für Umformtechnik und Gießereiwesen, Technische Universität München, Garching. FOSTA has accompanied the research project work and has organized the project funding from the Federal Ministry of Economics and Technology through the AiF as part of the programme for promoting industrial cooperation research (IGF) in accordance with a resolution of the German parliament.
Only available in german language.