Controlling damage in the production of hollow tubular shafts using radial forging, spline extrusion and hardening (T04#)

• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 278868966

In the transfer project, the process chain of incremental radial forging, spline extrusion and heat treatment for the production of monoblock tubular drive shafts is analyzed regarding the influence of each process step on the damage evolution and product performance. The focus here is particularly on the influence of cyclical loading and the Bauschinger effect on damage mechanisms and component performance. Further process-specific influences such as strain localization and strain rate on the damage evolution will also be analyzed. Together with GKN automotiv and Hexagon, a damage-controlled production route will be implemented.

• DFG Programme: CRC/Transregios (Transfer Project)
• Subproject of: TRR 188: Damage Controlled Forming Processes
• Applicant Institution: Technische Universität Dortmund, since 1/2025
• Business and Industry: GKN Driveline International GmbH, since 1/2025; Hexagon Manufacturing Intelligence GmbH ; Dr.-Ing. Ingo Neubauer, Director Research & Innovation ; Tempowerkring 19, 21079 Hamburg, since 1/2025
• Co-Applicant Institution: Rheinisch-Westfälische Technische Hochschule Aachen, since 1/2025
• Project Head: Professor Yannis Korkolis, Ph.D., since 1/2025