Process combination of lateral extrusion and shear forming with straight tool motion to manufacture crankshaft-like components

• Applicant: Professor Dr.-Ing. Mathias Liewald
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: from 2015 to 2018
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 276963522

Shear forming processes are not very common in the area of cold forging, due to the fact, that conventional component geometries produced by cold forging show a a rotationally symmetrical shape. Within this project, therefore, a novel shear forming processes should be developed to produce crankshaft-like components by a combination of cold lateral extrusion and shear forming. In contrast to the conventional process combination of shear forming and upsetting there is only a small deformation zone at the transition area of shaft extension and flange. In this area a compressive stress is superimposed and both the process forces and the occurring stresses are reduced. This additionally causes a lower edge rounding at the flange area. To investigate the impacts of several process parameters a simple and modular tool is suggested and should be designed and manufactured within this project. Such process parameters are for example the amount of lateral displacement or the displacement velocity respectively the counter pressure. The main project aim is to provide a basic and scientific knowledge for the combined forming process of lateral extrusion and shear forming with a straight tool motion.

• DFG Programme: Research Grants