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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
 
Final Report Year 2021

Final Report Abstract

The growing need for ecologically sustainable products and processes combined with an intense ecological competition poses a challenge for mechanical engineering. Function-integrated mechanical components are a central approach to reach sustainability goals. Forming technology – which is known for its efficient use of resources in the manufacturing of high-quality components – combines this known advantage with a high economic efficiency. Therefore, intuitively contradicting demands for economic and ecologic manufacturing are met. Conventional processes of sheet metal forming and bulk metal forming reach their limits when it comes to the production of geometrically challenging components. From this, the goal of SFB/Transregio 73 “Manufacturing of complex functional components with variants by using a new sheet metal forming process - Sheet-Bulk Metal Forming” was derived. In three periods, with the help of novel forming processes, the scientific basis was elaborated to meet the growing demand for individual, flexibly adjustable technological systems that show high levels of functionality. Sheet-bulk metal forming was defined as the application of bulk forming processes on sheet metal to shape functional elements by a local three-dimensional material flow. Within the first funding period, basic challenges that result from the combination of sheet and bulk metal forming were studied in the three sections processes, systems, and materials. In the section processes, the feasibility of sheet-bulk metal forming of functional elements from sheet metal was proven by a combined numerical-experimental approach. First insights into the challenges of tool load and material flow were established. To analyse the causes and origins of these problems, measuring and test systems that were specifically adjusted to the demands of sheet-bulk metal forming were studied in the projects of the section systems. Additionally, knowledge about the manufacturing of sheet-bulk metal forming tools was acquired. Here, the focus was on developing modified tool surfaces that counteract the challenges identified in the section processes. The section materials developed approaches to model the three-dimensional plasticity to describe the flow behaviour as well as the degradation during a three-dimensional material flow, which is characteristic for sheet-bulk metal forming processes. Within the second funding period, basic insights further were deepened. On the one hand, the mechanical transferability of DC04 that was used in the first funding period to DP600 was investigated. On the other hand, different sheet-bulk metal forming processes were combined to process chains. Additionally, the focus was on expanding process limits by applying workpiece- and tool-sided surface modifications. Requirements for tailored friction systems were derived by using simulations, and their effectiveness was verified experimentally. To do so, it was essential to study a constitutive friction law based on a half space model. This displays the tribology of sheet-bulk metal forming in a realistic manner, as conventional friction laws are only partially suitable for sheet-bulk metal forming. The third funding period focused on the workpiece service behaviour as well as on the long-term tool behaviour. Doing so, the complexity of the components manufactured by forming technology was increased to parts with executable gears, and their service behaviour was studied. Another basis for the investigation was modelling the damage behaviour. Additionally, the tool structuring and coating developed for extending the process limits were studied with regard to their effects on fatigue as well as wear. From the investigations, findings about a load adapted tool design were derived. Furthermore, the still ongoing transfer phase began during the third funding period. In here, knowledge about sheet-bulk metal forming was transferred to industry, and the elaborated expertise was verified under application-oriented conditions. Industry partners included suppliers of semi-finished products, software companies, component manufacturers, and companies of tool manufacturing. The transfer projects focused on applying structures and coatings to expand forming limits as well as on the investigation of processes in the manufacturing of abstracted industrial components. The developments in the field of sheet-bulk metal forming as a result of the SFB/Transregio 73 contribute to strengthening Germany as a manufacturing and technology location in an increasingly tougher international competition in an ecological and sustainable way, guaranteeing Germanys economic power in the long term.

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