12th Tooling Conference & Exhibition - Tooling 2022

Efficient processes offer a promising approach to meet requirements from global trends like sustainability or resource shortage. The process of orbital forming is established
for the manufacturing of functional components with a gradient in sheet thickness, like for example in a clutch. Nevertheless, the present tool setup disposes a lack in economic efficiency and is restricted by a maximum tumbling angle and a complex tool design. In this context, an innovative quasi-incremental process combination of tilting and turning is investigated with regard to the manufacturability of functional components with circumferen-
tial and cyclic symmetric elements. Due to the adapted kinematics, the contact area between tool and workpiece increases from the center in radial direction, resulting in a predominantly radial material flow. The aim within this research is the establishment of a comprehensive
process understanding of the forming parameters. Therefore, components out of the case-hardening steel C10 are manufactured and evaluated, regarding the geometrical and
mechanical properties. Different process strategies, like a varying number of tilting steps or the forming along different axis, are applied in order to improve the forming results. The
potential of the alternative tool setup for the manufacturing of the components is qualified by comparing the parts with conventionally orbital formed specimens.