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Department of Mechanical Engineering

Hot Plate Forging of Load-Adapted Gear Racks

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in
  • Sonderverfahren
  • RECIMP
  • Technologieentwicklung
a) Schematic depiction of the plate forging process, b) Effective plastic strain distribution in the gear rack after forming © IUL
a) Schematic depiction of the plate forging process, b) Effective plastic strain distribution in the gear rack after forming
Funding ReCIMP
Contact Dr.-Ing. Sebastian Wernicke

The innovative technology of plate forging enables the forming of load-adapted components. The application of bulk forming operations on sheet metal allows for a local increase of the sheet thickness t. Compared to components with homogeneous thickness distribution, a significant mass, material and, thus, CO2 reduction becomes attainable. This project focuses on hot plate forging of heat-treatable steels to reach the required hardness of gears already with the subsequent quenching process. The major challenge of this project is the avoidance of folding or insufficient form filling by a numerical optimization of the workpiece geometry. Beside the optimization of the workpiece geometry, also the impact of the process parameters on the process energy and tool load is investigated. Further investigations focus on an additional thermo-mechanical load reduction by the application of numerically optimized cooling channels.