TRR 73: Manufacturing of Complex Functional Components with Variants by Using a New Sheet Metal Forming Process - Sheet-Bulk Metal Forming
Materials Science and Engineering
Mathematics
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.
Publications
- Fully coupled frictional contact using elastic halfspace theory. Journal of Tribology 130(2008)3, S. 1-8
Willner, K.
(See online at https://doi.org/10.1115/1.2913537) - A damage coupled orthotropic finite plasticity model for sheet metal forming: CDM approach, Computational Materials Science, 48(2010), S. 150-165
Soyarslan, C.; Tekkaya, A.
(See online at https://doi.org/10.1016/j.commatsci.2009.12.022) - A posteriori control of modelling errors in linear elasticity. In: Proceedings in Applied Mathematics and Mechanics, 10(2010), S. 647-648
Große-Wöhrmann, A.; Blum, H.; Stiemer, M.
(See online at https://doi.org/10.1002/pamm.201010316) - Appliance of the Maturity Method in the Development of Endoscopic Geometry Inspection for Sheet-Bulk Metal Forming Tools. International Journal Total Quality Management & Excellence, 39(2011) 1, S. 11-16
Weckenmann, A.; Behrens, B.-A.; Reithmeier, E.; Akkasoglu, G.; Vucetic, M.; Ohrt, C.; Cahyono, T.; Hübner, S.; Kästner, M.
- Fundamental investigations on the material flow at combined sheet and bulk metal forming processes. Annals of the CIRP, 60(2011)1, S. 283-286
Merklein, M.; Koch, J.; Opel, S.; Schneider, T.
(See online at https://doi.org/10.1016/j.cirp.2011.03.146) - Influence of Ti/TiAlN-multilayer designs on their residual stresses and mechanical properties. Applied Surface Science, 257(2011), S. 8550-8557
Vogli, E.; Tillmann, W.; Herper, J.
(See online at https://doi.org/10.1016/j.apsusc.2011.05.013) - Verfahren zur Herstellung eines Bauteils und Umformwerkzeuge dazu, Patentanmeldung beim Deutschen Patent- und Markenamt, Aktenzeichen DE202011109135
Behrens, B.-A.; Hübner, S.; Vucetic, M.
- „A comparison between inverse form finding and shape optimization methods for anisotropic hyperelasticity in logarithmic strain space,“ PAMM, (2011)11, S. 367-368, 2011
Germain, S.; Steinmann, P.
(See online at https://doi.org/10.1002/pamm.201110175) - A cyclic twin bridge shear test for the identification of kinematic hardening parameters, International Journal of Mechanical Sciences 59 (2012), S. 31-43
Qing, Y.; Soyarslan C.; Güner, A.; Brosius, A.; Tekkaya, A. E.
(See online at https://doi.org/10.1016/j.ijmecsci.2012.02.008) - Bulk forming of sheet metal. Annals of the CIRP, 61(2012)2, S. 725-745
Merklein, M.; Allwood, J. M.; Behrens, B.-A.; Brosius, A.; Hagenah, H.; Kuzman, K.; Mori, K.; Tekkaya, A. E.; Weckenmann, A.
(See online at https://doi.org/10.1016/j.cirp.2012.05.007) - Orbital forming of tailored blanks from sheet metal. Annals of the CIRP 61(2012)1, S. 263-266
Merklein, M.; Plettke, R.; Opel, S.
(See online at https://doi.org/10.1016/j.cirp.2012.03.130) - New coating systems for temperature monitoring in turning processes. Surface & Coatings Technology, 215(2013), S. 376-380
Biermann, D.; Tillmann, W.; Herper, J.
(See online at https://doi.org/10.1016/j.surfcoat.2012.08.086) - Texture development and formability prediction for pre-textured cold rolled body-centred cubic steel, International Journal of Engineering Science, 68(2013), S. 24-37
Lehmann, E.; Faßmann, D.; Löhnert, S.; Schaper, M.; Wriggers, P.
(See online at https://doi.org/10.1016/j.ijengsci.2013.03.003) - Verfahren zur Herstellung eines Bauteils und kombiniertes Umformwerkzeug dafür. Patent: WO 2013017659 A1 (2013)
Behrens, B.-A.; Hübner, S.; Vucetic, M.
- Comparison of Different Biaxial Tests for the Inverse Identification of Sheet Steel Material Parameters, Strain, 50(2014), S. 389-403
Schmaltz, S.; Willner, K.
(See online at https://doi.org/10.1111/str.12080) - A grooved in-plane torsion test for the investigation of shear fracture in sheet materials, International Journal of Solids and Structures, 66(2015), S. 121-132
Q. Yin; Soyarslan, C.; Isik, K.; Tekkaya, A.
(See online at https://doi.org/10.1016/j.ijsolstr.2015.03.032) - In-plane biaxial compression and tension testing of thin sheet materials, International Journal of Solids and Structures, 66(2015)8, S. 111-120
Zillmann, B.; Wagner, M. F.-X. ; Schmaltz, S.; Schmidl, E.; Lampke, T.; Willner, K.; Halle, T.
(See online at https://doi.org/10.1016/j.ijsolstr.2015.03.031) - On the micro-deformation mechanisms active in high-manganese austenitic steels under impact loading, Materials Science and Engineering A, 632(2015), S. 29-34
Bal, B.; Gumus, B.; Gerstein, G.; Canadinc, D.; Maier, H. J.
(See online at https://doi.org/10.1016/j.msea.2015.02.054) - Plastic flow and its control in sheet-bulk metal forming of thinwalled functional components. Annals of the CIRP 64(2015)1, S. 245-248
Merklein, M.; Löffler, M.; Schneider, T.
(See online at https://doi.org/10.1016/j.cirp.2015.04.078) - Twinning activities in high-Mn austenitic steels under high-velocity compressive loading, Materials Science and Engineering A, 648(2015), S. 104-112
Gumus, B.; Bal, B.; Gerstein, G.; Canadinc, D.; Maier, H. J.; Guner, F.; Elmadagli, M.
(See online at https://doi.org/10.1016/j.msea.2015.09.045) - Wear Behavior of Bioinspired and Technologically Structured HVOF Sprayed NiCrBSiFe Coatings. In: Surface and Coatings Technology, 280(2015), S. 16-26
Stangier, D.; Tillmann, W.; Krebs, E.; Kersting, P.; Biermann, D.; Hagen, L.
(See online at https://doi.org/10.1016/j.surfcoat.2015.08.055) - A Non-invasive Heuristic Approach to Shape Optimization in Forming, Computational Mechanics, 57(2016), S. 169-191
Landkammer, P.; Steinmann, P.
(See online at https://doi.org/10.1007/s00466-015-1226-2) - Fracture toughness and failure limits in sheet metal forming, Journal of Materials Processing Technology, 234(2016), S. 249-258
Silva, M.B.; Isik, K.; Tekkaya, A. E.; Atkins, A. G.; Martins, P. A. F.
(See online at https://doi.org/10.1016/j.jmatprotec.2016.03.029) - Influences of Grinding with Toric CBN Grinding Tools on Surface and Subsurface of 1.3344 PM Steel. In: Journal of Materials Processing Technology, 229(2016), S. 541-548
Denkena, B.; Grove, T.; Lucas, H.
(See online at https://doi.org/10.1016/j.jmatprotec.2015.09.039) - Investigation of the tribological properties of high-feed milled structures and Cr-based hard PVD-coatings. In: Vacuum, 131(2016), S. 5-13
Tillmann, W.; Stangier, D.; Laemmerhirt, I.-A.; Biermann, D.; Freiburg, D.
(See online at https://doi.org/10.1016/j.vacuum.2016.05.024) - Local Sheet Thickening by In-Plane Swaging. International Journal of Mechanical Sciences, 119(2016), S. 59-67
Wernicke, S.; Sieczkarek, P.; Martins, P. A. F.; Tekkaya, A. E.
(See online at https://doi.org/10.1016/j.ijmecsci.2016.10.003) - Sheet-bulk metal forming. Production Engineering 10(2016)1
Merklein, M.; Tekkaya, A. E.; Behrens, B.-A. (Eds.)
(See online at https://doi.org/10.1007/s11740-016-0661-z) - Wear Behavior of Tribologically Optimized Tool Surfaces for Incremental Forming Processes. Tribology International, 104(2016), S. 64 – 72
Sieczkarek, P.; Wernicke, S.; Gies, S.; Tekkaya, A.; Krebs, E.; Wiederkehr, P.; Biermann, D.; Tillmann, W.; Stangier, D.
(See online at https://doi.org/10.1016/j.triboint.2016.08.028) - Adjustment of Friction by Duplex-Treated, Bionic Structures for Sheet-Bulk Metal Forming. Tribology International, 111(2017), S. 9-17
Tillmann, W.; Stangier, D.; Lopes-Dias, N.-F.; Biermann, D.; Krebs, E.
(See online at https://doi.org/10.1016/j.triboint.2017.02.037) - Experimental analysis of anisotropic damage in dual phase steel by resonance measurement, International Journal of Damage Mechanics, 26(2017)8, S. 1147-1169
Gerstein, G.; Clausmeyer, T.; Isik, K.; Nürnberger, F.; Tekkaya, A.; Bruchanov, A. A.; Maier, H.
(See online at https://doi.org/10.1177/1056789516650245) - Investigation of the tribolgocal behaviour of microstructures for controlling the material flow in sheet-bulk metal forming. CIRP Journal of Manufacturing Science and Technology, 22(2018), S. 66-75
Löffler, M.; Engel, U.; Willner, K.; Beyer, F.; Merklein, M.
(See online at https://doi.org/10.1016/j.cirpj.2018.05.002) - 3D Dynamic Crack under Cyclic Loading using XFEM: Numerical Treatment. PAMM 19(2019)1
Lyu, T.; Löhnert, S.; Wriggers, P.
(See online at https://doi.org/10.1002/pamm.201900147) - Manufacturing of tailored blanks by orbital forming with a two-sided material thickening. Journal of Materials Processing Technology, 287(2019), 116491
Vogel, M.; Merklein, M.
(See online at https://doi.org/10.1016/j.jmatprotec.2019.116491) - Verfahren und Vorrichtung zur Verdickung des Randes eines Blechkörpers. Europäische Patentschrift EP 3 323 527 B1 (2019)
Wernicke, S.; Sieczkarek, P.; Gies, S.; Tekkaya, A. E.
- Influence of Residual Stresses in heat-treated High-Speed Steels on the Adhesion of CrAlN Coatings. In: Journal of Heat Treatment and Materials, 75(2020), S. 163-176
Denkena, B.; Breidenstein, B.; Lucas, H.; Keitel, M.; Tillmann, W.; Stangier, D.
(See online at https://doi.org/10.3139/105.110413) - Measurement of the Beruforge 152DL thin-film lubricant using a developed thin-film thickness standard. Journal of Sensors and Sensor Systems, 9(2020), S. 157-165
Metzner, S.; Reuter, T.; Hausotte, T.
(See online at https://doi.org/10.5194/jsss-9-157-2020) - Static and oscillation superimposed ring compression tests with structured and coated tools for Sheet-Bulk Metal Forming. Journal of Manufacturing Processes, 55 (2020), S. 78-86
Behrens, B.; Meijer, A.; Stangier, D.; Hübner, S.; Biermann, D.; Tillmann, W.; Rosenbusch, D.; Müller, P.
(See online at https://doi.org/10.1016/j.jmapro.2020.04.007) - Tribological Studies on Multi-Coated Forming Tools. In: Journal of Manufacturing Processes, 49(2020), S. 141-152
Weikert, T.; Tremmel, S.; Stangier, D.; Tillmann, W.; Krebs, E.; Biermann, D.
(See online at https://doi.org/10.1016/j.jmapro.2019.11.021) - An innovative process combination of additive manufacturing and sheet bulk metal forming for manufacturing a functional hybrid part. Journal of Materials Processing Technology, 291(2021), 117032
Merklein, M.; Schulte, R.; Papke, T.
(See online at https://doi.org/10.1016/j.jmatprotec.2020.117032) - Force reduction by electrical assistance in incremental sheet-bulk metal forming of gears. Journal of Materials Processing Technology, 296(2021), 117194
Wernicke, S.; Hahn, M.; Detzel, A.; Tillmann, W.; Stangier, D.; Lopes Dias, N.F. Tekkaya, A. E.
(See online at https://doi.org/10.1016/j.jmatprotec.2021.117194) - Fringe projection profilometry in production metrology: A multi-scale comparison in sheet-bulk metal forming, Sensors, 21(2021)7, 2389
Hinz, L.; Metzner, S.; Müller, P.; Schulte, R.; Besserer, H.-B.; Wackenrohr, S.; Reithmeier, E.
(See online at https://doi.org/10.3390/s21072389) - Sheet Bulk Metal Forming. Lecture Notes in Production Engineering. 2021. ISBN 978-3-030-61902-2
Merklein, M.; Tekkaya, A. E.; Behrens, B.-A. (Eds.)
(See online at https://doi.org/10.1007/978-3-030-61902-2) - Simulation of wear and effective friction properties of microstructured surfaces. Wear, 464(2021), 203491
Schewe, M.; Wilbuer, H.; Menzel, A.
(See online at https://doi.org/10.1016/j.wear.2020.203491)
