Simulation des rotationskinematischen Umformens einer Seilrolle

This thesis presents a numerical investigation of the rotary-kinematic forming process to produce steel rope pulleys with defined groove profiles. The objective is to analyse the fundamental relationships between process parameters, material behaviour, and tool design to derive initial technical foundations for the development of an innovative forming machine. The process promises improved mechanical strength and increased service life of the components compared to conventional manufacturing methods such as casting or machining. The study begins with the validation of the simulation approach using a model from the literature, which is reproduced within the Simufact Forming 2022 software environment. Building on this, a novel concept for the hot forming of high-strength materials is developed and evaluated for its technical feasibility through extensive finite element analyses. The thesis focuses on determining the optimal number of forming stages, ensuring effective temperature control during the process, and identifying the geometric requirements for both workpiece and tools to enable a reliable and accurate groove formation. Through single-stage, two-stage, and four-stage simulations, the influence of key parameters on formability, temperature distribution, and final product quality is systematically analysed. The results demonstrate that a process-adapted tool design, targeted heat input, and optimized component geometry are critical to the successful implementation of this innovative forming method. The developed strategies reveal strong potential for increasing process efficiency by reducing the number of forming stages and shortening cycle times. This research thus provides a solid foundation for the further development of the rotary-kinematic forming process within the field of bulk metal forming and its transfer into industrial applications.