Marius Herrmann

Dry Rotary Swaging - Tube Forming

Rotary swaging is an incremental cold forming process for tubes and rods. The established processes use lubricants based on mineral oil. The functions of the lubricant are the reduction of friction, wear and tool load, furthermore it cools the tools and flushes the working zone. But the use of lubricant increases the cost due to additional process steps and lubricant is diverted with the work piece during the process. Thus from economic and ecological points of view it is worthwhile to eliminate the use of lubricant. Therefore it is necessary to realize the functions of the lubricant in another way. For example by means of coating and micro-structuring of the tools the friction and wear can be influenced. In this study dry rotary swaging is tested with conventional tools and machine settings. The analysis of the recorded process parameters and the formed geometry of the workpiece reveal the potential of dry rotary swaging, but also the difficulties that arise. Dry rotary swaging needs a modification of the process and system parameters as well as an adjustment of the tools.

Plastic deformation history in infeed rotary swaging process

In bulk forming processes, the net shape of a final product is achieved by plastic deformation as the material flows from the initial shape to the final shape of the workpiece. The material flow during the process is an important issue for its relationship with forging force, heat generation, microstructure transformation and energy consumption. Hence, the final properties of the product are directly influenced. Former researches showed that the material flow in the rotary swaging process is affected by different processing parameters like die angle, feeding velocity and friction condition. Thus, a profound knowledge of detailed material flow during the process is essential for a better understanding of the process. By using FEM, the material flow was investigated by the history of the plastic strain (PEEQ) development. In this study a 2D-axisymmetric model was built by using ABAQUS explicit. Both aluminum alloy (3.3206) and steel (1.0308) are studied with different feeding velocities and coefficients of ...

Dry rotary swaging with structured and coated tools

Rotary swaging is a cold bulk forming process for manufacturing of complex bar and tube profiles like axles and gear shafts in the automotive industry. Conventional rotary swaging is carried out under intense use of lubricant usually based on mineral oil. Besides lubrication the lubricant fulfills necessary functions like lubrication, flushing and cooling, but generates costs for recycling, replacement and cleaning of the workpieces. Hence, the development of a dry process design is highly desirable, both under economic and ecological points of view. Therefore, it is necessary to substitute the functions of the lubricant. This was realized by the combination of newly developed a-C:H:W coating systems on the tools to minimize the friction and to avoid adhesion effects. With the application of a deterministic structure in the forging zone of the tools the friction conditions are modified to control the axial process forces.In this study infeed rotary swaging with functionalized tools was experimentally investigated. Therefore, steel and aluminum tubes were formed with and without lubricant. Different structures which were coated and uncoated were implemented in the reduction zone of the tools. The antagonistic effects of coating and structuring were characterized by measuring the axial process force and the produced workpiece quality in terms of roundness and surface roughness. Thus, the presented results allow for further developments towards a dry rotary swaging process.Rotary swaging is a cold bulk forming process for manufacturing of complex bar and tube profiles like axles and gear shafts in the automotive industry. Conventional rotary swaging is carried out under intense use of lubricant usually based on mineral oil. Besides lubrication the lubricant fulfills necessary functions like lubrication, flushing and cooling, but generates costs for recycling, replacement and cleaning of the workpieces. Hence, the development of a dry process design is highly desirable, both under economic and ecological points of view. Therefore, it is necessary to substitute the functions of the lubricant. This was realized by the combination of newly developed a-C:H:W coating systems on the tools to minimize the friction and to avoid adhesion effects. With the application of a deterministic structure in the forging zone of the tools the friction conditions are modified to control the axial process forces.In this study infeed rotary swaging with functionalized tools was experimentally inve...

The influence of microstructure deformation on the corrosion resistance of cold formed stainless steel

Rotary swaging is an incremental cold forming process to produce axisymmetric workpieces from rods and tubes. The process also induces changes of the microstructure of the material depending on the process parameters. This in turn influences the mechanical properties like hardness as well as the electrochemical properties. As a result of changed electrochemical properties, the passivity of the material and thus the corrosion behavior changes. In order to investigate the influence of rotary swaging on the corrosion behavior of the stainless steel AISI304, deformed micro parts are electrochemically analyzed. The measurements reveal a dependency of corrosion rate and impedance on both feed velocity and final diameter of the rotary swaging process. A higher feed velocity decreases the corrosion rate and increases the impedance indicating a better resistance against corrosion as a side effect of rotary swaging.ddddddddddddddddddddddddddddddddddddddddddddd.

Electromagnetic Joining of Thin Sheets by Adapted Pulses

In this research the electromagnetic hemming of aluminum sheets with different sheet thickness (s0 = 100 μm and s0 = 300 μm) in varied stacking sequence is investigated. Though, the research was focused on hemming of sheets with a total stacking height lower than the skin depth based on the hypothesis that a full diffusion of both sheets positively influences the process of joining by electromagnetic forming.

Evolution of heat in dry rotary swaging

In dry metal forming processes, the heat dissipation is a critical issue. The cooling by the lubricant is missing. The different heat evolution affects the machine and the process and thus the final product. For the machine the thermal expansion is affected and needs to be considered. Also the tools can bear only a maximum heat load before they get damaged. Furthermore, the heat can influence the material properties like the flow stress if it exceeds a critical value. Furthermore, the process forces and the material flow are directly affected. In addition, heat modifies in combination with plastic strain the generated microstructure of the workpiece. If the heat is high enough even positive effects of cold forming like work hardening are drastically decreased. In summary, the heat evolution during lubricated and dry forming processes need to be investigated.The evolution of heat in rotary swaging was investigated with conventional tools and machine settings. This was realized by varying the feeding veloci...