Manufacturing of helical-toothed functional components from sheet metal by the development and analysis of a sheet-bulk metal forming process

• Applicant: Professorin Dr.-Ing. Marion Merklein
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 501091735

The overall objective is the determination of basic causal relationships of component and process parameters and the derivation of causalities in the manufacturing of helical geared components by means of sheet-bulk metal forming. For a process chain consisting of deep drawing, extrusion and upsetting, the process-specific challenges, a robust process window and the process limitations are to be developed. In order to enable the industrial application of sheet metal forming in the medium term for the production of helical components, the process has to be researched fundamentally and a continuous process understanding from process design to the production of ready-to-use components must be generated. In the presented project, a parameter-dependent process window with the achievable component properties is to be derived on the basis of a comprehensive process analysis. Furthermore, the extension of the achievable component functionality by forming helical gears with different modules and helix angles on semi-finished sheet metal parts by sheet‑bulk metal forming is fundamentally investigated. A two-stage process chain of deep drawing/extrusion and upsetting is used within the scope of the investigations. Using a numerical process model, a comprehensive process analysis will be carried out and basic interactions between the influencing parameters will be determined. Based on these findings, the reference process is designed and the experimental implementation is carried out. The simulation model is validated by means of process- and component-specific parameters such as process force, geometry and hardness distribution. The detailed investigation of the influence of the gear geometry and the materials used on the resulting component properties as well as the tool load identifies parameter-dependent process limits. With the conclusion of the first funding period, a number of sub-goals are targeted. Initially, process-specific challenges regarding the achievable flow paths and resulting cavity filling will be identified. In addition, an impact analysis of the helical gear’s specific material flow on the component’s properties such as work hardening and gear quality is to be carried out. Finally, an adapted process control to avoid machining in post-processing is developed.

• DFG Programme: Research Grants