Sciencedirect: Dry Rotary Swaging With Structured Tools
Sciencedirect: Dry Rotary Swaging With Structured Tools
Sciencedirect: Dry Rotary Swaging With Structured Tools
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ScienceDirect
Procedia CIRP 40 (2016) 653 – 658
13th Global Conference on Sustainable Manufacturing - Decoupling Growth from Resource Use
Abstract
Rotary swaging is a cold bulk forming process. The diameter of the workpiece is reduced incrementally by oscillating movement of the tools.
The established processes use lubricants which fulfill necessary functions such as lubricating, cooling and cleaning of the tools. Disadvantages
caused by the use of lubricant are costs of recycling, replacement of lost coolant and for the cleaning of the workpiece. To eliminate the
lubricant it is necessary to substitute the functions of the lubricant in other ways. For example by means of coating and structuring of the tools.
In this study infeed rotary swaging with structured tools is investigated using finite element simulations. Different structures are implemented
in the reduction zone of the tools. The influence is investigated by the radial and axial process forces. Additionally first structured tools are
manufactured and experimentally tested. The results of modeling and testing are discussed.
© 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
© 2016 The Authors. Published by Elsevier B.V.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing.
Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing
Keywords: cold forging; dry metal forming; structured tools
2212-8271 © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing
doi:10.1016/j.procir.2016.01.150
654 Marius Herrmann et al. / Procedia CIRP 40 (2016) 653 – 658
A amplitude
H overall heigth Fig. 5. Axial force.
L overall length
λ
α toolangle 3. Experimental procedure
λ wavelength
H 3.1. Setup
A
α
L To compare the results of the forming process with
structured tools as well as the workpiece results also
Fig. 3. Cosine geometry in the reduction zone of a structured tool. investigations with other tools were carried out. At first
conventional tools with a tungsten carbide layer (T1) in the
2.2. Results reduction zone are used (see Fig. 6 a)). Furthermore tools with
a smooth reduction zone (T2) were used to form tubes with
The simulation results are analyzed to observe the effects and without lubricant (see Fig. 6 b)).
of the geometrical parameters on the radial and axial force.
The considered axial and radial forces are the average of the
maximum axial and radial forces per stroke over the complete
quasi-steady state of the process, the radial force is considered
for one tool. The results of the comparative simulation
without steps are set to 100 %.
The radial and axial forces are represented versus the
amplitude A with the three different wavelengths. For the
radial process force no clear effect of the amplitude is
noticeable, see Fig. 4. But a taller wavelength leads to a lower
radial force. Only a reduction to FR = 96.8 % in comparison to
the simulation without structured reduction zone is possible a) b)
for a cosine shape with λ = 1.3 and A = 0.05 mm. A stronger
effect on the axial process force is shown in Fig. 5. While the Fig. 6. Rotary swaging tools; a) conventional tools with a tungsten carbide
amplitude rises the axial force decreases. Also a taller layer (T1), b) smooth tools (T2).
wavelength leads to a reduction of the axial force. A reduction
to FR = 34 % in comparison to the simulation without A first experimental implementation of a structure in the
structured reduction zone is achievable however for reduction zone for rotary swaging tools are realized.
λ = 1.1 mm and A = 0.2 mm. The axial force is reduced by the Therefore a cosine shape with wavelength of λ = 1.3 mm and
benefited material flow. This is due to the geometry since the a amplitude of A = 150 μm is chosen. The tool T3 consisting
flow is less impeded due to the space generated by the cosine of the material 1.2379 is visualized in Fig. 7.
geometry as well as the altered distribution of strain.
656 Marius Herrmann et al. / Procedia CIRP 40 (2016) 653 – 658
0.5 mm
Fig. 13. Workpiece surface after forming with T1dry (vf = 500 mm/min).
Fig. 10. roughness of the workpieces with a feed velocity of vf = 500 mm/min
for T1, T2 and T3, wet and dry.
Acknowledgements