Sheet-Bulk Metal Forming
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Sheet-Bulk Metal Forming Marion Merklein Lehrstuhl f€ ur Fertigungstechnologie (LFT), Universita¨t Erlangen-N€ urnberg, Erlangen, Germany
of end products, SBMF can also be used to produce tailored blanks with adjusted properties for usage in subsequent manufacturing processes (Tan et al. 2008).
Theory and Application Synonyms Plate forging
Definition Sheet-bulk metal forming (SBMF) processes are defined as forming of sheets with an intended three-dimensional material flow as in bulk forming processes (Merklein et al. 2012). As semifinished product, sheets with an initial thickness of 1–5 mm are used and subjected to one or several conventional bulk forming operations. Typical applications of SBMF include the forming of local functional elements on blank parts or the intended and locally restricted alteration of the sheet thickness in order to produce highly functional integrated parts out of sheet metal (Fig. 1) (Mori 2012). Further complexity can be achieved by the combination of SBMF processes with traditional sheet forming operations like bending or deep drawing, which is generally possible for most applications (Merklein et al. 2012). Besides the fabrication
Classification According to DIN 8582 (2003), forming processes are categorized with respect to their stress states during the forming operation. This classification is not applicable to SBMF processes due to the fact that characteristics of multiple processes can merge in some cases and due to the missing consideration of the geometry of the semifinished part in question. Kudo (1980) proposed a different approach that enables a general classification of SBMF processes as a function of the semifinished parts in question, the resulting product geometry, and the strain state in relation to the main axis of the part. Standring (1999) proposed another, more detailed classification, which also uses the contact normal vector, as well as the ratio of the contact areas in the forming zone in comparison to the remaining contact area as criteria. However, since both approaches are kept very general, an exact assignment of process characteristics to the process class SBMF is not possible. In order to solve this challenge, Merklein et al. (2011) proposed a classification in respect to the tool motion as is displayed in Fig. 2. According to this
# CIRP 2015 The International Academy for Production Engineering et al. (eds.), CIRP Encyclopedia of Production Engineering, DOI 10.1007/978-3-642-35950-7_16822-1
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Sheet-Bulk Metal Forming
Sheet-Bulk Metal Forming, Fig. 1 Examples of sheet-bulk metal forming parts with functional elements (Feintool 2015)
Sheet-Bulk Metal Forming, Fig. 2 Process classification and characteristics of common sheet-bulk metal forming operations (Merklein et al. 2011)
classification, upsetting, ironing, forging, and coining can be assigned to the group of linear tool motion, whereas flow forming, orbital forming, and boss forming processes possess a rotational tool motion. As Fig. 2 depicts, with the exception of orbital forming and boss f
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