TRR 73:  Manufacturing of Complex Functional Components with Variants by Using a New Sheet Metal Forming Process - Sheet-Bulk Metal Forming

• Subject Area: Mechanical and Industrial Engineering ; Materials Science and Engineering ; Mathematics
• Term: from 2009 to 2020
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 68237143

The transregional CRC 73 was initiated to establish the scientific basics to meet the growing market for individualised technological systems of high functional density by the application of forming technologies. However, classic sheet and bulk forming processes reach their limits regarding thin-walled functional components. The transregional CRC 73 provides a major contribution to the devel-opment of forming technology and its range of components in consideration of ecological and re-source-efficient production by applying bulk forming processes to sheet metal. The research aims on the investigations to increase the functionality of components made from sheet metal. In the first funding period basic questions were addressed, that resulted from the combination of sheet and bulk forming operations. In the second funding period the scientific results from the first funding period were combined to process chains while the complexity of the parts was increased at the same time.The vision of the transregional CRC 73 for its third funding period is to research the influence of the manufacturing process on the performance characteristics of the workpieces. In this context the ef-fect of hardening and damage introduced by the manufacturing processes on the performance char-acteristics is of special interest. In combination with a continued increase in workpiece complexity this will escalate the challenges in designing the process chain as well as the involved processes. The focus of the research work in the original and still applied three areas of processes, systems and material will be the scientific analysis of the product life cycle of sheet-bulk metal formed workpieces. The development in the field of sheet-bulk metal forming will help to secure and strengthen the pro-duction and technology location Germany in an ever increasing international competition, which shall improve its economic power.

• DFG Programme: CRC/Transregios

Completed projects

• A01 - Process combination for manufacturing of teethed, thin-walled functional components out of tailored blanks (Project Heads Lechner, Michael ;  Merklein, Marion ;  Plettke, Raoul )
• A02 - Forming of complex functional elements on sheet metal (Project Heads Andreas, Kolja ;  Engel, Ulf ;  Merklein, Marion )
• A03 - Parameter identification for maturity assessment of metal forming processes using fuzzy logic uncertainty analysis (Project Heads Brenner, Peter-Frederik ;  Weckenmann, Albert )
• A04 - Fundamental research and process development for the manufacturing of load-optimized parts by incremental sheet-bulk metal forming (Project Head Tekkaya, A. Erman )
• A05 - Development of model adaptive simulation techniques for forming processes of complex functional components with complicated design details (Project Heads Blum, Heribert ;  Rademacher, Ph.D., Andreas )
• A06 - Strategies for the function-oriented optical inspection of high-precision sheet bulk metal forming parts (Project Head Hausotte, Tino )
• A07 - Improvement of combined cutting and deep drawing processes by means of overlaying dynamic process forces (Project Heads Behrens, Bernd-Arno ;  Hübner, Sven )
• B01 - Simultaneous development of a self-learning engineering assistance system (Project Head Wartzack, Sandro )
• B02 - Machining of molds with filigree structures for sheet-bulk metal forming (Project Heads Biermann, Dirk ;  Wiederkehr, Petra )
• B03 - Generation of predetermined surface structures by simulation-based process and tool engineering (Project Heads Biermann, Dirk ;  Surmann, Tobias )
• B04 - Tribological DLC-coatings in combination with surface texturing for forming tools to increase lifetime and to improve process quality (Project Heads Tremmel, Stephan ;  Wartzack, Sandro )
• B05 - Application of nanostructured thin bionic layers to enhance the wear and friction behaviour of forming tools by thin-walled sheet forming (Project Head Tillmann, Wolfgang )
• B06 - Endoscopic geometry inspection by modular fibre-optic sensors (Project Heads Kästner, Markus ;  Reithmeier, Eduard )
• B07 - Analysis of horizontal loads in sheet-bulk metal forming and their consideration in simulation (Project Heads Behrens, Bernd-Arno ;  Krimm, Richard )
• B08 - Grinding strategies for local and stress orientated subsurface-modification of sheet-bulk metal forming tools (Project Head Denkena, Berend )
• C01 - Constitutive friction law for the description and optimization of tailored surfaces (Project Heads Andreas, Kolja ;  Engel, Ulf ;  Merklein, Marion ;  Willner, Kai )
• C02 - Prediction of eigenstresses and fatigue strength of sheet bulk metal forming parts (Project Heads Löhnert, Stefan ;  Wriggers, Peter )
• C03 - Parameter and shape optimization using finite elasto-plasticity (Project Heads Steinmann, Paul ;  Willner, Kai )
• C04 - Analysis of load history dependent evolution of damage and microstructure for the numerical design of sheet - bulk metal forming processes (Project Heads Clausmeyer, Till ;  Nürnberger, Florian ;  Schaper, Mirko ;  Soyarslan, Celal ;  Tekkaya, A. Erman )
• C05 - Local surface treatment by atmospheric plasma nitriding to increase the hardness and the wear resistance of highly stressed tool- and component regions following of the metal forming process (Project Heads Bach, Friedrich-Wilhelm ;  Hassel, Thomas )
• C06 - Fatigue behaviour of sheet-bulk metal formed workpieces (Project Heads Maier, Hans Jürgen ;  Nürnberger, Florian ;  Rodman, Dmytro )
• C07 - Mechanism-based modelling of wear in sheet-bulk metal forming (Project Head Menzel, Andreas )
• T02 - Manufacturing of Tailored Blanks by orbital forming for industrial applications (Project Head Lechner, Michael )
• T03 - Tool sided surface modifications in industrial environment (Project Head Merklein, Marion )
• T04 - Incremental Sheet-Bulk Metal Forming by application of thermal controlled grading mechanisms (Project Head Tekkaya, A. Erman )
• T05 - Extension of the process limits by integration of oscillation tool into an industry-oriented sheet-bulk metal forming process (Project Heads Behrens, Bernd-Arno ;  Hübner, Sven )
• T06 - Numerical calculation of the tool wear in industrial cold forming processes by further develop-ment of a wear model (Project Head Behrens, Bernd-Arno )
• T08 - Lifetime-compliant process design for the manufacturing of sheet-bulk metal formed components (Project Heads Maier, Hans Jürgen ;  Nürnberger, Florian )
• T09 - On-site processing of complex and cost-intensive capital investments (Project Head Denkena, Berend )
• T10 - Development of a manufacturing process for functional components with a varying sheet thickness profile (Project Heads Lechner, Michael ;  Merklein, Marion )
• T12 - Development of an acoustic measurement methodology for the determination of microstructural damage (Project Heads Maier, Hans Jürgen ;  Nürnberger, Florian )
• Z - Central Tasks (Project Head Merklein, Marion )

• Applicant Institution: Friedrich-Alexander-Universität Erlangen-Nürnberg
• Co-Applicant Institution: Gottfried Wilhelm Leibniz Universität Hannover; Technische Universität Dortmund
• Spokesperson: Professorin Dr.-Ing. Marion Merklein