Control of component properties in rotary swaging process

• Applicants: Dr.-Ing. Jérémy Epp; Professor Dr.-Ing. Bernd Kuhfuß
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing ; Mechanical Properties of Metallic Materials and their Microstructural Origins
• Term: since 2017
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 374789876

Rotary swaging is an established incremental cold forming production technique. First attempts to describe the material modifications such as work hardening and residual stress generation as well as the incremental material flow leading to a material flow history are already known. Due to its high variability of the material flow for the same final shape, rotary swaging is a particularly suitable forming process in order to generate residual stresses by process control. The final aim of this project is to describe the interrelation between the material flow, which is controlled by the process control, the resulting material modifications - in particular the residual stress state - and the resulting mechanical properties of the components. As a result, it should be possible to predict the mechanical properties depending on the rotary swaging process parameters or the other way round, to define the required process parameters in order to achieve the desired mechanical properties of the components. This goal is based on the hypothesis that on the one hand, the mechanical properties correlate with the generated material modifications in terms of work hardening and residual stress generation, and on the other hand that these material modifications are resulting from the material flow history of the process. To achieve the overall objective, four sub-objectives are defined for the third funding period: Design and optimization of the rotary swaging process for multi-stage production; component-adapted adjustment of residual stresses; verification and prediction of property improvements under realistic service conditions; design and transferability of the overall method.

• DFG Programme: Priority Programmes
• Subproject of: SPP 2013: The utilization of residual stresses induced by metal forming