Numerical Calculation of Tool Wear in Industrial Cold Forming Processes Using the Further Development of Wear Modelling

authored by: Bernd Arno Behrens, Hendrik Wester, Tim Matthias, Sven Hübner, Philipp Müller, Jonas Wälder
Abstract: The technology of sheet-bulk metal forming (SBMF) offers the possibility of manufacturing metal parts from a flat semi-finished product with functional secondary forming elements. Therefore, this technology provides the advantages of a resource-efficient production by shortening the process chain, saving materials and reducing the production costs. However, high contact normal stresses arise in SBMF-processes, leading to increased tool wear. The project T06 deals with the further development of numerical wear calculation for processes with high contact normal stresses. The numerical wear modelling is performed using the adapted friction law according to Archard, based on the friction shear stress. This model is applied exemplarily for the wear calculation in an industry-oriented process based on an extrusion process of the company Fischerwerke GmbH. An experimental setup is developed which simulates the industrial application at laboratory level. A hydraulically working oscillating device is installed in this test stand. The influence of a superimposed oscillation on the process characteristics of the Fischer process is investigated. The focus is on a reduction of the average forming force and a related reduction of the tool loads.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
External Organisation(s): fischerwerke GmbH & Co. KG
Type: Contribution to book/anthology
Pages: 535-552
No. of pages: 18
Publication date: 2021
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Industrial and Manufacturing Engineering, Economics, Econometrics and Finance (miscellaneous), Safety, Risk, Reliability and Quality
Electronic version(s): https://doi.org/10.1007/978-3-030-61902-2_24 (Access: Closed)
: Details in the research portal "Research@Leibniz University"

BibTeX

@inbook{c728af917d7a4780820c2c0aa29fecec,
title = "Numerical Calculation of Tool Wear in Industrial Cold Forming Processes Using the Further Development of Wear Modelling",
abstract = "The technology of sheet-bulk metal forming (SBMF) offers the possibility of manufacturing metal parts from a flat semi-finished product with functional secondary forming elements. Therefore, this technology provides the advantages of a resource-efficient production by shortening the process chain, saving materials and reducing the production costs. However, high contact normal stresses arise in SBMF-processes, leading to increased tool wear. The project T06 deals with the further development of numerical wear calculation for processes with high contact normal stresses. The numerical wear modelling is performed using the adapted friction law according to Archard, based on the friction shear stress. This model is applied exemplarily for the wear calculation in an industry-oriented process based on an extrusion process of the company Fischerwerke GmbH. An experimental setup is developed which simulates the industrial application at laboratory level. A hydraulically working oscillating device is installed in this test stand. The influence of a superimposed oscillation on the process characteristics of the Fischer process is investigated. The focus is on a reduction of the average forming force and a related reduction of the tool loads.",
author = "Behrens, {Bernd Arno} and Hendrik Wester and Tim Matthias and Sven H{\"u}bner and Philipp M{\"u}ller and Jonas W{\"a}lder",
note = "Funding Information: Acknowledgment. This study was supported by the German Research Foundation (DFG) within the scope of the Transregional Collaborative Research Centre for sheet-bulk metal forming (TCRC 73, Subproject T06) under grant number 417860413. The authors are in addition grateful to all laboratory assistants and students who supported the realization of this work.",
year = "2021",
doi = "10.1007/978-3-030-61902-2_24",
language = "English",
series = "Lecture Notes in Production Engineering",
publisher = "Springer Nature",
pages = "535--552",
booktitle = "Lecture Notes in Production Engineering",
address = "United States",
}