Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

Fundamental investigations on the manufacturing of cyclic symmetrical components with variants by using sheet-bulk metal forming

Datum: 04.12.2015



  • Prof. Dr.-Ing. habil. M. Merklein
  • Prof. Dr.-Ing. Dr.-Ing. E.h. A. E. Tekkaya

The application of bulk forming operations on sheet metal represents a new process class. The so-called sheet-bulk metal forming is very challenging in terms of the process and tool design. At the beginning of the investigations, neither the influencing factors nor layout guidelines were known for such a forming process. In the focus of the present work is a reference process for the manufacturing of circumferential gearings on a sheet metal blank with a thickness of 2.0 and 3.0 mm. In particular the realization of an adequate mould filling in compliance with the maximum process forces has been emerged as a challenge. Therefore, several ways to control the material flow have been developed. A very promising approach to control the material flow is a local adaptation of the tribological conditions. A method for process modelling, which has been applied in the context of the work, is the mathematical construction of a parametric model of the reference process. Using this model in combination with the Monte Carlo method and known variations of the process parameters, a calculation of the process result quantities is possible for the first time in sheet-bulk metal forming.