The manufacturing of gear elements by forming offers advantages regarding the resulting mechanical properties of the functional components. One possible approach is offered by the incremental sheet-bulk metal forming of gears using a linear motion punch. This method is highly flexible in terms of shape and position of the functional elements to be produced, but inefficient from an economical point of view due to the high process time. This paper presents a new sheet-bulk gear forming process using rotating tools in order to speed up the manufacturing process of load-adapted gears. Here, different concepts with rotating tools being synchronized and non-synchronized to the workpiece are investigated to form high-strength, load-adapted gears made of bainitic steel BS600. The focus is on the analysis of the occurring material flow which is examined by means of finite element analysis and microstructural investigations to ensure the manufacture of fully functional geared components by this sheet-bulk metal forming process.
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ASME 2017 12th International Manufacturing Science and Engineering Conference collocated with the JSME/ASME 2017 6th International Conference on Materials and Processing
June 4–8, 2017
Los Angeles, California, USA
Conference Sponsors:
- Manufacturing Engineering Division
ISBN:
978-0-7918-5072-5
PROCEEDINGS PAPER
Material Flow Analysis for the Incremental Sheet-Bulk Gearing by Rotating Tools
Sebastian Wernicke,
Sebastian Wernicke
TU Dortmund University, Dortmund, Germany
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Peter Sieczkarek,
Peter Sieczkarek
TU Dortmund University, Dortmund, Germany
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Joshua Grodotzki,
Joshua Grodotzki
TU Dortmund University, Dortmund, Germany
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Soeren Gies,
Soeren Gies
TU Dortmund University, Dortmund, Germany
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Nooman Ben Khalifa,
Nooman Ben Khalifa
TU Dortmund University, Dortmund, Germany
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A. Erman Tekkaya
A. Erman Tekkaya
TU Dortmund University, Dortmund, Germany
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Sebastian Wernicke
TU Dortmund University, Dortmund, Germany
Peter Sieczkarek
TU Dortmund University, Dortmund, Germany
Joshua Grodotzki
TU Dortmund University, Dortmund, Germany
Soeren Gies
TU Dortmund University, Dortmund, Germany
Nooman Ben Khalifa
TU Dortmund University, Dortmund, Germany
A. Erman Tekkaya
TU Dortmund University, Dortmund, Germany
Paper No:
MSEC2017-3029, V001T02A061; 8 pages
Published Online:
July 24, 2017
Citation
Wernicke, S, Sieczkarek, P, Grodotzki, J, Gies, S, Ben Khalifa, N, & Tekkaya, AE. "Material Flow Analysis for the Incremental Sheet-Bulk Gearing by Rotating Tools." Proceedings of the ASME 2017 12th International Manufacturing Science and Engineering Conference collocated with the JSME/ASME 2017 6th International Conference on Materials and Processing. Volume 1: Processes. Los Angeles, California, USA. June 4–8, 2017. V001T02A061. ASME. https://doi.org/10.1115/MSEC2017-3029
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