Investigation of the Influence of Slightly Increased Process Temperatures on the Extrusion of Functional Aluminum Components in Sheet-Bulk Metal Forming

By using high-strength aluminum, weight savings can be achieved. However, limited formability of these alloys at room temperature is a challenging aspect regarding the manufacturing of components with filigree functional elements within sheet-bulk metal forming. So as to derive detailed process knowledge and to improve the achievable process results, forward extrusion of geared components made of EN AW 6082 sheets at room temperature is investigated within this work. Furthermore, robust large-scale industrial cold forming is a demanding task, as tool temperatures increase over time due to forming and frictional heat, leading to varying material and process properties. In order to determine measures for the compensation of these fluctuations, additional experiments are carried out with slightly increased tool temperatures. By analyzing workpiece and process related parameters for both sets of experiments, potential approaches to control the outcome of forming operations under variable conditions are discussed.