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Material flow analysis for the incremental sheet-bulk gearing by rotating tools

Research output: Contributions to collected editions/works › Article in conference proceedings › Research › peer-review

Authors

  • Sebastian Wernicke
  • Peter Sieczkarek
  • Joshua Grodotzki
  • Soeren Gies
  • Noomane Ben Khalifa
  • A. Erman Tekkaya

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 nonsynchronized to the workpiece are investigated to form highstrength, 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.

Original languageEnglish
Title of host publicationProceedings of the ASME 12th International Manufacturing Science and Engineering Conference - 2017 : Processes
Volume1
PublisherThe American Society of Mechanical Engineers (ASME)
Publication date2017
Article numberV001T02A061
ISBN (print)9780791850725
ISBN (electronic)9780791850725
DOIs
Publication statusPublished - 2017
Externally publishedYes
Event6th International Conference on Materials and Processing - MSEC 2017 - Los Angeles, United States
Duration: 04.06.2017 → 08.06.2017
Conference number: 6
http://www.asme.org/events/msec2017

Bibliographical note

Aufsatz. Nr. MSEC2017-3029 - V001T02A061

    Research areas

  • FEM, Gearing, Incremental forming, Sheet-bulk metal forming (SBMF)
  • Engineering

Other publications by the same author(s)

Analysis of tailored residual stress fields of deep rolled AA2024 sheets

Lehmann, J., Pöltl, D., Esterl, F., Kashaev, N. & Ben Khalifa, N., 09.2025, In: International Journal of Material Forming. 18, 3, 12 p., 66.

Research output: Journal contributions › Journal articles › Research › peer-review

Comparison of different machine control modes during friction extrusion of AA2024

Rana, H., Chan, C., Suhuddin, U. F. H., Ben Khalifa, N. & Klusemann, B., 2025, 28th International ESAFORM Conference on Material Forming, ESAFORM 2025. Carlone, P., Filice, L. & Umbrello, D. (eds.). Association of American Publishers, p. 772-779 8 p. (Materials Research Proceedings; vol. 54).

Research output: Contributions to collected editions/works › Article in conference proceedings › Research › peer-review

Comprehensive analysis of the forming zone and improvement of diameter reduction prediction in the dieless wire drawing process

Braatz, M., Bohlen, J. & Ben Khalifa, N., 15.04.2025, In: Journal of Manufacturing Processes. 139, p. 210-223 14 p.

Research output: Journal contributions › Journal articles › Research › peer-review

Connecting texture development to die design in extruded flat products

Esterl, F., Nienaber, M., Bohlen, J. & Ben Khalifa, N., 31.01.2025, In: Journal of Manufacturing Processes. 134, p. 891-903 13 p.

Research output: Journal contributions › Journal articles › Research › peer-review

Die geometry influence on the texture and microstructure development during extrusion of AZ31 and ZK60 magnesium alloy chips

Hendriok, L., Nienaber, M., Kurz, G. & Ben Khalifa, N., 01.2025, In: Materials and Design. 249, 13 p., 113545.

Research output: Journal contributions › Journal articles › Research › peer-review

DOI

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