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Importance of material and friction characterisation for FE-aided process design of hybrid bevel gears

Autoren:Behrens, B.-A.; Bouguecha, A.; Bonk, C.; Matthias, T.
Kategorie:Zeitschriften/Aufsätze (reviewed)
Veröffentlichung:AIP Conference Proceedings 1896, 190016 (2017)


Solid-forming components are often used in areas where they are subjected to very high loads. For most solid components locally divergent and sometimes contradictory requirements exist. Despite these contradictory requirements, almost exclusively monomaterials are nowadays used for the production of solid components. These components often reach their material-specific limits because of increasing demands on the products. Thus a significant increase in product quality and profitability would result from combining different materials in order to create tailored properties. In the Collaborative Research Center (CRC) 1153 “Tailored Forming” at the Leibniz Universität Hannover, this topic is investigated. The primary objective of the CRC 1153 is to develop and investigate new tailored manufacturing processes to produce reliable hybrid solid semi-finished components. In contrast to existing production processes of hybrid solid components, semi-finished workpieces in the CRC 1153 are joined before the forming phase. Thus, it will be possible to produce complex and highly stressable solid components made of different metals, which cannot be produced yet with the current used technologies. In this work the material and friction characteristics are investigated and the forming tool for the production of hybrid bevel gears made of different steel alloys (C22 and 41Cr4) is designed by numerical simulations. For this purpose, flow curves of both materials are determined by means of upsetting tests at process-related forming temperatures and strain rates. The temperature range for the forming process of the semi-finished product is determined by comparing the respective flow curves regarding similar flow stresses. Furthermore, the friction between the tool and the joining materials is investigated by means of ring upsetting tests at a process-relevant temperature. Finally, a stress analysis of the forming tools is carried out.