SFB 708: 3D-Surface Engineering of Tools for Sheet Metal Forming - Manufacturing, Modelling, Machining
Computer Science, Systems and Electrical Engineering
Mechanical and Industrial Engineering
Final Report Abstract
During forming processes in the automotive and aerospace industry, the productivity of tool systems plays a critical role in the fabrication of car body panels as well as structural elements made of sheet metals. In general, the tools in the medium or large-lot production are large and usually have a complex geometry. These tools have to provide a long service life during the forming of high strength sheet metals. In addition, the formed sheet metal components have to achieve a high dimensional accuracy. The de-velopment and manufacturing of forming tools is a time-consuming and cost-intensive process. Advanc-ing tool wear does not only lead to a significant quality loss of the formed components, but in the worst case also result in a wear-related machine breakdown. Apart from the necessity to exchange the tools, the rework of defectively formed sheet metal parts causes considerable costs. The optimal design of forming tools with regard to their wear resistance and their shape accuracy is of particular importance. Against this background, the Collaborative Research Centre (SFB) 708 has developed a novel manufac-turing methodology for the economical and resource-efficient production of highly wear-resistant surfaces on complex forming tools. The major research objective was placed on novel materials and processes within the field of thermal spraying. These approaches were used to apply hard and wear resistant near-net-shape coatings with a high surface quality and controlled heat input onto the surface of forming tools. To achieve these goals, an efficient path planning and process management for coating with industrial robots were introduced. Moreover, the finishing processes of the coating surface, the tribological behavior of the coated tools during forming, as well as the component’s quality and the spring-back of the sheet metals after forming were investigated. The novel manufacturing method of 3D Surface Engineering, developed by the SFB 708, is characterized by the continuously integrated simulation and virtual modeling of all manufacturing steps. The purpose of the virtual modeling was to optimize and to connect the individual manufacturing techniques (milling, thermal spraying, rolling and grinding) to a process chain, as well as to obtain a simulation-based valida-tion of the forming operation with the corresponding tool. The overall objectives of the novel simulation-aided manufacturing process chain in the SFB 708 were on the one hand, the production of a sophisticat-ed and highly wear-resistant tool to form high-strength sheet metals. On the other hand, a small number of iteration steps and a simultaneous reduction of trial-and-error experiments should be provided during the development stage of the tools. This comprises of a variety of sophisticated questions related to ma-terial engineering, manufacturing, forming, mathematical modeling, simulation and optimization as well as the use of efficient algorithms and data structures. These questions were subjected to the projects in the SFB and were successfully answered by an interdisciplinary cooperation between engineers and meth-odologists from the fields of mechanical engineering, mathematics, computer science and statistics at the TU Dortmund University. Fundamentals in the fields of materials engineering and process-technology were initially developed in the first project phase. At the same time, modelling approaches for the production and application of coatings on forming tools, for the process management and the fin-ishing of the coatings as well as for the forming and spring-back behavior of high-strength sheets were investigated. Major goals of the second project phase were the application of the obtained results in terms of the coating and finishing procedures to tools with more complex surfaces. In addition the process-related influencing factors and disturbances should be analyzed. Based on the simulation and modelling as well as on the knowledge about relevant process parameters and material characteris-tics, an adjustment and optimization of the manufacturing processes could be performed. By means of the novel and innovative SFB 708 process chain, consisting of an efficient offline path planning and pro-cess management as well as a suitable surface finishing concept, a real and complex 3D forming tool could be successfully coated with a near-net-shape and highly wear resistant surface. The tribological behavior of the coated tool in the forming process was analyzed in subsequent experimental tests. Thereby, the suitability, respectively the potential of the approach chosen in the SFB, could be proven. The objectives of the final funding phase included the completion of the 3D-Surface-Engineering method and its application on real 3D-forming tools with free formed geometrics. This included the depo-sition of finely structured near-net-shape coatings with a controlled heat input into the surface, online pro-cess monitoring and the characterization of coatings as well as the finishing of the coated tool surface. The complete illustration and optimization of the process chain was realized by coupling the manufactur-ing processes with analytical methods, simulations and modelling. This also allowed a practicable and substantial transfer of the results to industrial practices.
Publications
- Asymmetric melting behavior in twin wire arc spraying with cored wires. Journal of Thermal Spray Technology; 2008; S. 974-982
Tillmann, W.; Vogli, E.; Abdulgader, M.
- Implicit Finite Element Schemes for Compressible Gas and Particle-Laden Gas Flows. Dissertation; 2009
Gurris, M.
- Parameter optimization for spray coating. Advances in Engineering Software; 2009; S. 1078-1086
Kout, A.; Müller, H.
- Robotergestuetzte, endkonturnahe Beschichtung komplexer Oberflaechen mit thermisch gespritzten WC- basierten Verschleißschutzschichten. Thermal Spray Bulletin; 2010; S. 44-53
Tillmann, W.; Kuhlenkoetter, B.; Vogli, E.; Baumann, I.; Scheele, C.; Krebs, B.
- High wear resistant deep drawing tools made of coated polymers. CIRP Annals - Manufacturig technology; 2011; S. 311-314
Witulski, J.; Trompeter, M.; Tekkaya, A. E.; Kleiner, M.
- Implicit Finite Element Schemes for Stationary Compressible Particle-laden Gas Flows. Journal of Computational and Applied Mathematics; 2011; S. 5056-5077
Gurris, M.; Kuzmin, D; Turek, S.
- Particle Size Distribution of the Filling Powder in Cored Wires: Its Effect on Arc Behavior, In-Flight Particle Behavior and Splat Formation. Journal of Thermal Spray Technology; 2011; S. 1544-1016
Tillmann, W.; Abdulgader, M.
- Strategies for springback compensation regarding process robustness. Production Engineering - Research and Development; 2011; S. 49-57
Gösling, M.; Kracker, H.; Brosius, A.; Kuhnt, S.; Tekkaya, A. E.
- Homogenization modeling of thin-layer-type microstructures. International Journal of Solids and Structures; 2012; S. 1828-1838
Klusemann, B.; Svendsen, B.
- Influence of handling parameters on coating characteristics in order to produce near-net-shape wear resistant coatings. Journal of Thermal Spray Technology; 2012; S. 644-650
Tillmann, W.; Krebs, B.
- Robotergestützte Bearbeitung: Aktuelle Entwicklung in Industrie und Forschung. Spanende Fertigung - Prozesse, Innovationen, Werkstoffe; 2012; S. 246-252
Brüninghaus, J.; Hypki A.; Krewet, C.; Kuhlenkötter, B.
- Thermisch beschichtete, faserverstärkte Polymerwerkzeuge für die Umformung höherfester Blechwerkstoffe. Dissertation; Shaker; 2012
Kolbe (geb. Witulski), J.
- Acquisition and optimization of three-dimensional spray footprint profiles for coating simulations. Journal of Thermal Spray Technology; 2013; S. 1044-1052
Wiederkehr, T.; Müller, H.
(See online at https://doi.org/10.1007/s11666-013-9927-6) - Application and analysis of force control strategies to deburring and grinding. Modern Mechanical Engineering; 2013; S. 11-18
Domrös F.; Krewet C.; Kuhlenkötter B.
- Capabilities of a Process Simulation for the Analysis of Five-Axis Milling Processes in the Aerospace Industry. 18th International Seminar of High Technology; Piracicaba, Brazil; 2013
Kersting, P.; Odendahl, S.
- Friction analysis of thermally sprayed coatings finished by ball burnishing and grinding. Production Engineering - Research and Development; 2013; S. 601-610
Tekkaya, A.E.; Kleiner, M.; Biermann, D.; Hiegemann, L.; Rausch, S.; Franzen, V.; Kwiatkowski, L.; Kersting, P.
- Iterative, simulation-based shape modification by free-form deformation of the NC programs. Advances in Engineering Software; 2013; S. 63-71
Sacharow, A.; Odendahl, S.; Peuker, A.; Biermann, D.; Surmann, T.; Zabel, A.
(See online at https://doi.org/10.1016/j.advengsoft.2012.11.007) - Neural Network Development and Training for the Simulation of Dynamic Robot Movement Behavior. Recent Advances in Robotics and Automation; Springer-Verlag GmbH, Berlin Heidelberg; 2013; S. 1-13
Johnen, B.; Scheele, C.; Kuhlenkötter, B.
- A Procedure for the Evaluation and Compensation of Form Errors by Means of Global Isometric Registration with Subsequent Local Reoptimization. Production Engineering. Research and Development; 2014; S. 81-89
Klein, L.; Wagner, T.; Buchheim, C.; Biermann, D
(See online at https://doi.org/10.1007/s11740-013-0510-2) - Efficient Large-Scale Coating Microstructure Formation Using Realistic CFD Models. Journal of Thermal Spray Technology; 2014; S. 1-13
Wiederkehr, T.; Müller, H.
(See online at https://doi.org/10.1007/s11666-014-0194-y) - Grinding process simulation of freeformed WC-Co hard material coated surfaces on machining centers using poisson-disk sampled dexel representations. CIRP Journal of Manufacturing Science and Technology; 2014; S. 168-175
Siebrecht, T.; Rausch, S.; Kersting, P.; Biermann, D.
(See online at https://doi.org/10.1016/j.cirpj.2014.01.001) - Metal Matrix Composites Deposition in Twin Wire Arc Spraying Utilizing an External Powder Injection Composition. Journal of Thermal Spray Technology; 2014; S. 40-50
Tillmann, W.; Abdulgader, M.; Hagen, L.; Nellesen, J.
(See online at https://doi.org/10.1007/s11666-013-0044-3) - Quantitative Improvement of Tool Impact Paths Defined by Isolines of Scalar Functions on Triangular Mesh Workpiece Surfaces. The International Journal of Advanced in Manufacturing Technology; 2014; S. 237-25
Kout, A.; Müller, H
(See online at https://doi.org/10.1007/s00170-013-5152-1) - Simulation of grinding processes using finite element analysis and geometric simulation of individual grains. Production Engineering Research and Development; 2014; S. 345-353
Siebrecht, T.; Biermann, D.; Ludwig, H.; Rausch, S.; Kersting, P.; Blum, H.; Rademacher, A.
(See online at https://doi.org/10.1007/s11740-013-0524-9) - Sliding and Rolling Wear Behavior of HVOF Sprayed Coatings Derived from Conventional, Fine and Nanostructured WC-12Co Powders. Journal of Thermal Spray Technology; 2014; S. 262-280
Tillmann, W.; Baumann, I.; Hollingsworth, P.; Hagen, L.
(See online at https://doi.org/10.1007/s11666-013-0038-1) - Tool-adaptive Offset Paths on Triangular Mesh Workpiece Surfaces. Computer-Aided Design; 2014; S. 61-73
Kout, A.; Müller, H.
(See online at https://doi.org/10.1016/j.cad.2014.01.009) - Adaptive Optimal Control of the Obstacle Problem. SIAM Journal on Scientific Computing; 2015; S. A918-A945
Meyer, C.; Rademacher, A.; Wollner, W.
(See online at https://doi.org/10.1137/140975863) - Effect of Residual Stress on the Wear Resistance of Thermal Spray Coatings. Journal of Thermal Spray Technology; 2015; S. 1-10
Luo, W.; Selvadurai, U.; Tillmann, W.
(See online at https://doi.org/10.1007/s11666-015-0309-0) - Effiziente, GPU-basierte Simulation thermischer Spritzprozesse. Dissertation; 2015; S. 1-268
Wiederkehr, T.
- Hierarchical Finite Element Methods for Compressible Flow Problems. Dissertation; 2015
Bittl, M.
- In Situ Wear Test on Thermal Spray Coatings in a Large Chamber scanning electron microscope. Journal of Thermal Spray Technology; 2015; S. 263-270
Luo, W.; Tillmann, W.; Selvadurai, U.
(See online at https://doi.org/10.1007/s11666-014-0163-5) - Influence of the Handling Parameters on Residual Stresses of HVOF-sprayed WC- 12Co Coatings. Surface and Coatings Technology; 2015; S. 30-35
Selvadurai, U.; Hollingsworth, P.; Baumann, I.; Hussong, B.; Tillmann, W.; Rausch, S.; Biermann, D.
(See online at https://doi.org/10.1016/j.surfcoat.2014.11.055) - Prediction of roughness after ball burnishing of thermally coated surfaces. Journal of Materials Processing Technology; 2015; S. 193-201
Hiegemann, L.; Weddeling, C.; Ben Khalifa, N.; Tekkaya, A.E.
(See online at https://doi.org/10.1016/j.jmatprotec.2014.11.008) - Sequential designs for sensitivity analysis of functional inputs in computer experiments. Reliability Engineering & System Safety; 2015; S. 260-267
Fruth, J.; Roustant, O.; Kuhnt, S.
(See online at https://doi.org/10.1016/j.ress.2014.07.018) - Springback prediction and reduction in deep drawing under influence of unloading modulus degradation. International Journal of Material Forming; 2015; S. 1-15
ul Hassan, H.; Maqbool, F.; Güner, A.; Hartmaier, A.; Ben Khalifa, N.; Tekkaya, A. E.
(See online at https://doi.org/10.1007/s12289-015-1248-5) - Strong Stationarity Conditions for a Class of Optimization Problems Governed by Variational Inequalities of the Second Kind. Journal of Optimization Theory and Applications; 2015; S. 1-35
De los Reyes, J. C.; Meyer, C.
(See online at https://doi.org/10.1007/s10957-015-0748-2) - Studying the Effect of the Air-Cap Configuration in Twin-Wire Arc-Spraying Process on the Obtained Flow Characteristics Using Design of Experiment Oriented Fluid Simulation. Journal of Thermal Spray Technology; 2015; S. 46-54
Tillmann, W.; Abdulgader, M.; Anjami, N.; Hagen, L.
(See online at https://doi.org/10.1007/s11666-014-0183-1) - Thermally sprayed finestructured WC-12Co coatings finished by ball burnishing and grinding as an innovative approach to protect forming tools against wear. Surface and Coatings Technology; 2015; S. 134-141
Tillmann, W.; Hollingsworth, P.; Baumann, I.; Hiegemann, L.; Weddeling, C.; Tekkaya, A.E.; Rausch, S.; Biermann, D.
(See online at https://doi.org/10.1016/j.surfcoat.2014.06.039) - Deep Drawing of High Strength Tailored Blanks by using tailored Tools. Materials; 2016; S. 1-14
Mennecart, T.; ul Hassan, H.; Güner, A.; Ben Khalifa, N.; M.Hosseini
(See online at https://doi.org/10.3390/ma9020077) - Finite element simulation of coatinginduced heat transfer: application to thermal spraying processes. Meccanica, 51 (2016) S. 291-307
Berthelsen, R.; Tomath, D.; Denzer, R.; Menzel, A.
(See online at https://doi.org/10.1007/s11012-015-0236-7)
