Untersuchungen zum Rundkneten von Mikrobauteilen

Abstract

The demand for miniature components, as well as the requirement for high functional density paired with high precision, is increasing steadily from year to year. For example, saving resources and cost-effectiveness can be mentioned as reasons for this trend. This high demand paves the way for the development of new manufacturing processes or for the research and adaptation of existing processes for the purpose of miniaturization. Due to the specific advantages, such as the generation of residual compressive stresses in the components or the ability to produce complex geometries with adapted properties, the suitability of rotary swaging for micro manufacturing has been explored in recent years. Rotary swaging is very well-established in the macro range, especially in the automotive industry, and has also been explored. However, because it is well known that scaling a process from the macro to the micro range cannot always be readily accomplished, it is of particular interest to fill the knowledge gap of downsizing related to the swaged parts. The focus of the presented investigations was the understanding of the process in general as well as the phenomenon occurring in the component, the determination of the process limits and thus the productivity and the characterization of the products. A simulation of the process with the FE method showed the complexity of the material behavior, from which, for example, explanations for the occurrence of certain types of failure or for the hardening of the components can be derived. Furthermore, an unfavorable material flow was identified as the most common cause of failure in the micro rotary swaging process. Measures to control it were developed and experimentally investigated. An increase in the output rate without significant deterioration of the component quality was a target. This work shows that rotary swaging has a high potential for micro manufacturing, since different materials, ferrous and non-ferrous metals, can be easily formed and thus very high component strengths can be achieved.