Investigation of the influence of an oscillation superposition on the wear behaviour in an industrial-like process

Abstract

In cold forging processes as well as in sheet-bulk metal forming, vast contact stresses result in severe tool wear and thus in tool failures. In order to achieve a sustainable production, a new manufacturing process is developed within the subproject T06 in the transregional collaborative research centre 73 at the Institute of Forming Technology and Machines (IFUM). In this subproject the influence of an oscillation superposition on a forming process is investigated. The new type of sheet-bulk metal forming (SBMF) process manufactures a component with internal and external gearing. Contact normal stresses and thus tool wear could be reduced by applying an oscillation superposition in the main force flow of the machine. To verify the positive results in other processes, the oscillation method is applied to an industrial-like process based on anchor bolt manufacturing of Fischerwerke GmbH & Co. KG. For this purpose, a representative tool system is developed using numerical simulation. The numerical simulation is also used to investigate resulting local contact stresses and relative sliding velocities. Furthermore, cylinder compression tests with and without oscillation superposition are conducted for the workpiece stainless steel 1.4362 (AISI S32304), in order to qualify the reduction of contact stress.