P 1064 – Economic production of weight-optimized and load-adapted functional components by incremental sheet-bulk metal forming

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P 1064 – Economic production of weight-optimized and load-adapted functional components by incremental sheet-bulk metal forming

The objective of the research project is the economic production of industrially relevant functional components by incremental sheet-bulk metal forming by usin  the   advantages of strain hardening. With regard to the current state of the incremental  forming approach, the processing time has to be reduced significantly in order to  achieve realistic cycle times.
With the acceleration of the process, changes of the thermal boundary conditions of the process are associated and need to be analyzed in the context of this research project. Applying new strategies, the effects on the adjustable component properties shall be determined experimentally and numerically so that the associated negative aspects of a subsequent heat treatment can be avoided and the costs can be reduced.
The challenge is to maximize and optimize the material-dependent effect of strain hardening for a possible industrial application. By near net shaping and an optimal utilization of the material and its hardening, the negative aspects occurring during a conventional manufacture can be avoided. For the complex process with cyclic loading and unloading and mutual influence of the process parameters, fundamental challenges arise to the tool load, the process parameters to be adjusted, and to the whole tribological system, which requires the use of new tool steels as well as a suitable lubrication method.
The focus of the investigations is on the determination and the control of the arising  conflict between the forming temperature as a result of the accelerated process cycle and the specifically adjusted strain hardening.

Published in:
August 2020

Authors:
Prof. Dr.-Ing. Dr.-Ing. E.h. A. E. Tekkaya, Dr.-Ing. P. Sieczkarek, Dr.-Ing. S. Gies, S. Wernicke M. Sc.