Producing load-adapted and functionally integrated components by flexible and resource efficient processes has gained importance within industries like the automotive sector in recent years. A promising new class of processes that enables a local adaption of the sheet thickness is Sheet-Bulk Metal Forming (SBMF). While the incremental procedure (iSBMF) only requires a moderate forming force, forming of high strength steels leads to a tool load resulting in a significantly reduced tool life. One approach to reduce tool loads is the utilization of the so called electroplastic effect (EPE). This study for the first time identifies the potential of the EPE on a temporary reduction of the forming force during the iSBMF of gears targeting an improvement of the tool life. The steel grades DC04 and HSM700 HD are characterized considering the EPE under uniaxial tension. Based on the characterization, the current density and temperature increase are modelled numerically and analytically for the incremental gear forming process. Moreover, the impact of EPE on strain hardening, grain texture and forming force is determined. By a local insulation of the forming tool based on a PVD coating and the application of an electrical current, a temporary force reduction of up to 55 % is observed whereas the strain hardening effect remains almost unaffected.

近年来，通过灵活且资源高效的过程生产适应负载和功能集成的组件已在汽车等行业中变得越来越重要。钣金成形（SBMF）是一种有前途的新方法，可以使薄板厚度局部适应。虽然增量过程（iSBMF）仅需要适度的成形力，但高强度钢的成形会导致工具负荷，从而显着缩短工具寿命。减少工具负荷的一种方法是利用所谓的塑性效应（EPE）。这项研究首次确定了EPE在齿轮的iSBMF期间暂时降低成形力的潜力，旨在延长刀具寿命。考虑到单轴张力下的EPE，对DC04和HSM700 HD钢牌号进行了表征。在此基础上，对增量齿轮成形过程的电流密度和温度升高进行了数值和解析建模。此外，确定了EPE对应变硬化，晶粒组织和成形力的影响。通过基于PVD涂层的成型工具的局部绝缘和施加电流，可以观察到暂时力降低高达55％，而应变硬化效果几乎不受影响。