SFB 1153:
Process Chain for Manufacturing of Hybrid High Performance Components by Tailored Forming
Subject Area
Mechanical and Industrial Engineering
Materials Science and Engineering
Term
since 2015
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 252662854
The Collaborative Research Center (CRC) 1153 aims at identifying the potential of hybrid bulk-metal components based on a novel process chain and at developing the necessary manufacturing processes. In contrast to the conventional manufacturing and production processes for hybrid bulk-metal components where the joining process only takes place during forming or at the end of the manufacturing chain, the CRC uses semi-finished products that are joined before the forming process. This allows for the production of components that meet the local requirements of different structural and functional areas within themselves much better than mono-material components. By combining different materials within a component, the weight or the costs of the component can be reduced while maintaining or improving performance either by the local use of lightweight materials or by combining it with high-quality alloys. In comparison with existing manufacturing processes, the simple geometry of the semi-finished products in the tailored forming process chain facilitates handling and a reliable production of a cohesive joining zone. By means of specifically controlling the material flow during the subsequent forming, the resulting joining zone geometry can be influenced as well, which is currently not feasible in conventional joining processes. The thermomechanical influence during forming also improves the quality of the joining zones. The innovative approach of the CRC 1153 includes an integral view of the manufacturing and development process from the semi-finished workpiece to the usable component by establishing the necessary process guidelines and deriving specific laws. The technology-readiness level of tailored forming processes developed to date is to be further increased in the third funding period. To this end, the robustness of the individual and overall process chain is to be increased and the characterisation options and modelling approaches expanded, among other things. The physical and digital consolidation of the decentrally developed processes will enable the verification of the robustness of the process chain in serial forging tests. At the same time, the integration of additional measurement technology as well as the consistent acquisition and provision of relevant process data permits the derivation of control algorithms beyond the individual process steps, thus reproducibly increasing the process parameter space for the production of hybrid high-performance components. In order to be able to transfer the developed innovations into industrial practice, evaluation possibilities are required to assess the economic and ecological added value of the developed technology. For this purpose, ecological influencing variables will be taken into account in previous economic evaluation approaches, which, together with the technological enhancements, prove the overall potential of the new technology.
DFG Programme
Collaborative Research Centres
Current projects
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A01 - Influence of the local microstructure on the workability of extruded composite materials
(Project Heads
Barton, Sebastian
;
Behrens, Bernd-Arno
;
Bouguecha, Anas
;
Klose, Christian
;
Maier, Hans Jürgen
;
Uhe, Johanna
)
-
A02 - Heat treatment for load-adjusted material properties of tailored forming components
(Project Heads
Herbst, Sebastian
;
Nürnberger, Florian
)
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A03 - Ultrasound-assisted laser welding for the generation of formable mixed compounds
(Project Heads
Hassel, Thomas
;
Kaierle, Stefan
;
Wallaschek, Jörg
)
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A04 - Spatial adaption of material properties of forming parts using surfacing techniques to produce graded hybrid components
(Project Heads
Hassel, Thomas
;
Overmeyer, Ludger
)
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B01 - Incremental forming of hybrid billets using cross wedge rolling
(Project Head
Stonis, Malte
)
-
B02 - Die forging of coaxially arranged hybrid semi-finished parts
(Project Head
Behrens, Bernd-Arno
)
-
B03 - Determination of the deformability and the resulting component properties in the impact extrusion of serially arranged hybrid semi-finished parts
(Project Heads
Behrens, Bernd-Arno
;
Brunotte, Kai
)
-
B04 - Function-oriented planning of the machining process of hybrid components
(Project Heads
Breidenstein, Bernd
;
Denkena, Berend
;
Prasanthan, Vannila
)
-
B05 - Machine tool technologies for productive machining of hybrid components
(Project Heads
Bergmann, Benjamin
;
Denkena, Berend
)
-
C01 - Experimental-numerical method to predict damage and failure of interphases in hybrid workpieces during forming
(Project Heads
Behrens, Bernd-Arno
;
Bouguecha, Anas
)
-
C02 - Configuration and design of hybrid solids
(Project Heads
Gembarski, Paul Christoph
;
Lachmayer, Roland
;
Mozgova, Iryna
)
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C03 - Hybrid areas in components with a high fatigue life under stress induced by combinations of rolling, torsion and structural loads
(Project Heads
Pape, Florian
;
Poll, Gerhard
)
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C04 - Modelling and simulation of joint interfaces during tailored forming
(Project Heads
Aldakheel, Fadi
;
Junker, Philipp
;
Löhnert, Stefan
;
Wriggers, Peter
)
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C05 - Multi-scale geometry measurement of material joining areas
(Project Heads
Hinz, Lennart
;
Kästner, Markus
;
Reithmeier, Eduard
)
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C07 - Flexible handling of forge-warm hybrid components
(Project Head
Raatz, Annika
)
-
C08 - Value-based production management for resource-efficient manufacturing of hybrid high-performance components
(Project Heads
Kuprat, Vivian
;
Nyhuis, Peter
)
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INF - Vocabulary-oriented research data management for tailored forming process chains
(Project Heads
Auer, Sören
;
Mozgova, Iryna
;
Uhe, Johanna
)
-
S01 - Flexible process chain for the resource-efficient production of tailored forming components
(Project Heads
Behrens, Bernd-Arno
;
Raatz, Annika
)
-
T03 - High-temperature-resistant tool edge layer by applying the Tailored Forming technology to hot forging tools
(Project Heads
Behrens, Bernd-Arno
;
Brunotte, Kai
)
-
T05 - Repair of roller bearing damage using tailored forming to extend service life
(Project Heads
Hassel, Thomas
;
Pape, Florian
;
Poll, Gerhard
)
-
Z01 - Central Task
(Project Head
Behrens, Bernd-Arno
)
Completed projects