Wear investigation and prediction in gear forming processes with oscillating ram movement


By using cold forging processes the demand for high-quality components can be satisfied. Studies show that the forming force can be reduced during the process by oscillating stroke characteristics. Earlier investigations show that the force reduction is caused by a relubrication. The process window can be enlarged using oscillating ram movements. Investigations of the wear characteristics are necessary for oscillating ram movements to improve simulation quality and process dimensioning. Taking advantage of the results of this investigation, a wear forecast can be implemented.


The aim of this project is the generation of a wear forecast for oscillating ram movements. For this, the acting wear mechanisms will be studied and parameters for the prediction are determined. In addition, the prediction will be validated by experiments in the industrial environment.


Wear investigations will be carried out at the machine laboratory of the institute PtU as well as in an industrial environment. Verification of the laboratory test results will be executed this way, too. Numerical simulations will be implemented at the same time and optimized according to test results. Goals of the investigation are the identification and analysis of wear mechanisms during gear forming processes with oscillating ram movements. Therefore sliding compression tests and gear forming experiments with an active strip wound container will be done. The empirical findings from the investigation should result into a wear prediction model for the process. Finally verifications in an industrial environment will be performed.


The Institute for Production Engineering and Forming Machines would like to thank the German Research Foundation (DFG) as well as the Felss System GmbH for their support in this project.