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Metal Forming and Casting
At
utg
we manufacture wheel bodies only. We look into
the manufacturing techniques deep drawing and fine
blanking. These manufacturing techniques are already
taken into account during the wheel bodies’ design phase.
Manufacturing of the gear ring and joining it with the wheel
body is conducted at our partner institute IWT in Bremen.
Finally, there will be endurance trials at another partner
institute, the FZG in Munich, to ensure the durability of the
designed gear wheels.
Conclusion
Within the research project Lightweight Forging we have
developed and manufactured promising designs for light-
weight gear wheels. Weight savings of 35% (189 g) with
the stapled sheet metal wheel body have been achieved.
The numerical investigations predict the load capacities
of the new gear wheel designs and a solid gear wheel to
be on the same level. This allows replacement of the solid
gear wheel with one of the new designs.
Projects
■■
Prevention of Surface Deflections of Sheet Metal Parts
(AiF)
■■
Improving the Time Dependent Evaluation Method of
Tests for the Determination of the Forming Limit Curve
and Developing of a Numerical Equivalent Model (AiF)
■■
Optimized Risk Management in Press-shops for Mini-
mizing Breakdown Costs in Case of Facility Downtime
(BMW AG)
■■
Hole Roller Clinching of Multi-Material-Lightweight
Joints (DFG)
■■
Connection Optimization of Progressive Die Compo-
nents (AiF)
■■
Inline-Quality Control in Pressing Tools (BMW AG)
■■
Stiffening of Cambered Sheet Metal Designs: Numeric
Bead Optimization by a Coupled Algorithm Considering
Nonlinear Forming Limits (DFG)
■■
Anisotropic Generalized Forming Limit Concept (DFG)
■■
Intelligent Lightweight Design Through Multi-compo-
nent Processes (AiF)
■■
Production-compatible Design of Deep-drawn Parts
(BFS)
■■
Process-integrated Compensation of Geometrical
Deviations for Bulk Forming (IMU)
■■
Suitable Representation of Sharp Character Lines for
Large Scale Production (BMW AG)
■■
Improvement of High Strain Rate Superplasticity of
Aluminum Materials by Equal Channel Angular Pressing
of Sheet Metal Products (DFG)
Figure 1: Multi-component gear wheel, consisting of gear ring (dark-grey)
and wheel body (light grey) with stapled sheet metal wheel body. The single
sheet metal layers are fine blanked at
utg
, Munich. Gear ring and wheel
body are joined immediately after the gear ring’s heat treatment at IWT,
Bremen. Connectors hold the sheet metal layers in place during transport.
They will be removed for the endurance trials. In mass production, the
sheet metal layers will be connected via stacking after cutting.
Figure 2: Multi-component gear wheel (sectional view) with deep drawn
wheel body. The wheel body is divided horizontally and therefore consists
of two separate parts.
Figure 3: Multi-component gear wheel with stapled sheet metal wheel body
Results
To date we have successfully manufactured a gear wheel
with stapled sheet metal wheel body (figure 3). First deep-
drawn wheel bodies have been produced as well. As soon
as gear wheels with both types of wheel bodies exist, we
will conduct static tests to investigate the force needed to
push the wheel body out of the gear ring in axial direction
and how much torque the gear wheels can transmit. This
will allow us to validate our numerical results.