Numerical and experimental investigation of a backward extrusion process for forming geared components from coil

Abstract. Stricter political regulations, increasing ecological awareness of society as well the pursuit for higher performance components motivate lightweight construction. Functional integration is one way to realize design, resulting in increased demands on component geometry. Sheet-bulk metal forming (SBMF) offers potential enable an economic and production functional through short process chains. SBMF from coil also provides additional advantages regarding high output quantity cycle times. However, industrially application limited due tool load coil-specific challenges like anisotropic material flow, which negatively affects part accuracy. In this study, a backward extrusion with gearing investigated. Therefore, numerical model was built validated based experimental results. order generate profound understanding, combined numerical-experimental approach chosen fundamental analysis. The influence semi-finished product geometry investigated by rotationally symmetric, pre-cut blanks material. different sheet geometries compared component- process-side target quantities. results indicate flow challenge, leads direction-dependent forming.