Sheet Bulk Metal Forming: Research Results of the TCRC73

Preface
	Introduction
	Structure
	Institutions
	People
	Leaderboard
	Project Heads
	Qualified Young Researchers
	Output
	References
Contents
Process Combination for the Manufacturing of Toothed, Thin-Walled Functional Elements by Using Process Adapted Semi-finished Products
	Abstract
	1 Introduction
	2 State of the Art
	3 Objective and Methodology
	4 Results
		4.1 Geometry of the Tailored Blanks and Manufacturing Processes
		4.2 Manufacturing of Tailored Blanks - Upsetting
		4.3 Manufacturing of Tailored Blanks – Orbital Forming
		4.4 Manufacturing of Tailored Blanks – Flexible Rolling
		4.5 Deep Drawing of Open Carriers and Realization of Material Allocation
		4.6 Processing of Conventional and Tailored Blanks in a Combined Deep Drawing and Upsetting Process
		4.7 Investigations on the Manufacture of Thick-Walled Carrier Elements
		4.8 Combination of Different Functional Elements
		4.9 Manufacturing of Components with Functional Elements on Both Sides of the Cup Wall
		4.10 Manufacturing of Functional Components with Involute Gearing
	5 Conclusion and Outlook
	Acknowledgment
	References
Forming of Complex Functional Elements on Sheet Metal
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Results
		3.1 Process Design and Modelling
			3.1.1 Numerical Process Modelling
			3.1.2 Validation of the Numerical Process Models
		3.2 Process Analysis
			3.2.1 Basic Analysis of the Material Flow
			3.2.2 Geometry-Specific Correlations
		3.3 Measures to Avoid Unintended Material Flow and Increase Die Filling
			3.3.1 Load Approach
			3.3.2 Geometric Approach
			3.3.3 Tribological Approach
	4 Summary
		4.1 Component-Specific Relationships
		4.2 Process- and Tool-Specific Relationships
	5 Conclusion and Outlook
	Acknowledgment
	References
Fundamental Research and Process Development for the Manufacturing of Load-Optimized Parts by Incremental Sheet-Bulk Metal Forming
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Results
		3.1 Fundamental Process Understanding
			3.1.1 Load-Adaption by in-Plane Thickening
			3.1.2 Load-Adaption by Edge Thickening
			3.1.3 Forming of Functional Elements
		3.2 Mechanical and Geometrical Properties
			3.2.1 Impact of Cyclic Loads on Strain Hardening Behavior
			3.2.2 Edge Thickening
			3.2.3 Mechanical Properties of Functional Elements
			3.2.4 Geometrical Properties of Functional Elements
		3.3 Strategies to Reduce the Tool Load
			3.3.1 Adaption of the Forming Tool
			3.3.2 Load Reduction by Stress Superposition
			3.3.3 Strain Path Dependent Forming Force
			3.3.4 Electrical Assistance in ISBMF
			3.3.5 Force Reduction by Hybridization of the Component
	4 Conclusion and Outlook
	Acknowledgment
	References
Strategies for Function-Oriented Optical Inspection of Formed Precision Workpieces
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Description of the Developed Measurement Setup
		3.1 Calibration and Registration Procedure
		3.2 Measurement of the Positioning Accuracy of the Hexapod
			3.2.1 Determining the Positioning Accuracy of the Hexapod Using a Coordinate Measuring Machine
			3.2.2 Determining the Positioning Accuracy of the Hexapod Using a Two-Beam Laser Interferometer
		3.3 Stereovision Approach to Determine Point Quality and Calibration Results
		3.4 Determination of the Influence of the Lubricant Used Beruforge 152DL on Optical Measurements
			3.4.1 Coaxial Interferometric Layer Thickness Measurement System
			3.4.2 Description of the Developed Thin Film Thickness Standard
			3.4.3 Procedure for Determining the Refractive Index with the Developed Standard
			3.4.4 Effects of the Lubricant in the Thin-Film Range on Fringe Projection Measurements
		3.5 Deflectometric Approach to Extend the Existing Measurement System for the Detection of Directed Reflections
	4 Conclusion and Outlook
	Acknowledgment
	References
Dynamic Process Forces
	Abstract
	1 Introduction
	2 Objective and Methodology
		2.1 Investigations of Superimposed Oscillation, Tool Coating and Structuring in Ring-Compression Tests
			2.1.1 Ring Compression Tests
			2.1.2 Experiments Without Tailored Surfaces
		2.2 Numerical Consideration of the Friction Parameters
		2.3 Experimental Investigations with Tailored Surfaces
		2.4 Transfer of the Findings to the SBMF Process
			2.4.1 Tailored Surfaces
			2.4.2 Superimposed Oscillation
		2.5 Numerical Investigations of the Tool Wear
			2.5.1 Theoretical Principles of Numerical Wear Calculation
			2.5.2 Numerical Results of Wear Calculation
		2.6 Investigations of Residual Formability
			2.6.1 Stress-Based Fracture Models
			2.6.2 Investigation of Fracture Behaviour
	3 Conclusion and Outlook
	Acknowledgment
	References
Simultaneous Development of a Self-learning Engineering Assistance System
	Abstract
	1 Introduction
	2 System Architecture of the Self-learning Engineering Assistance System
	3 Usage of Data in the Self-learning Engineering Assistance System
		3.1 Data Generation
		3.2 Product and Process Data Model
		3.3 Applied Data Mining Methods
		3.4 Knowledge Acquisition and Management
	4 Synthesis of Sheet-Bulk Metal Forming Parts
		4.1 Classification System for Design Elements
		4.2 Design Configurator and User Interface
		4.3 Parameter Access
		4.4 Synthesis of Parts
	5 Analysis of Sheet-Bulk Metal Forming Parts
		5.1 Metamodel-Based Analysis of Parts
		5.2 Types of Metamodels
		5.3 Global and Local Metamodels for Sheet-Bulk Metal Formed Parts
			5.3.1 Global Metamodels
			5.3.2 Local Metamodels
			5.3.3 Applications of Neural Networks
		5.4 Predictions and Visualization
		5.5 Sensitivity Analysis
	6 Pareto Optimization of Sheet-Bulk Metal Formed Parts
		6.1 Pareto Optimized Tailored Blanks
		6.2 Solutions Spaces for Part Design
	7 Conclusion and Outlook
	Acknowledgment
	References
Machining of Molds with Filigree Structures for Sheet-Bulk Metal Forming
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Results
		3.1 Micromilling of Hardened Tool Steels
			3.1.1 Process Design
			3.1.2 Surface Quality and Process Optimization
			3.1.3 Design of Cutting Edges for Hard Micromachining
		3.2 Micromachined Surface Structures
			3.2.1 Derivation of the Bionic and Technological Surface Structures
			3.2.2 Manufacturing Methods and New Approaches for the Process Design
			3.2.3 Tribology and Wear of Surface Structures
	4 Conclusion and Outlook
	Acknowledgment
	References
Generation of Predetermined Surface Structures by Simulation Based Process and Tool Design When Milling Free-Formed Surfaces
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Surface Structuring by Milling with Intentionally Invoked Chatter
		3.1 Process Design
		3.2 Simulation Based Process Optimization
		3.3 Transfer of the Results to Sheet-Bulk Metal Forming
		3.4 Application of Functional Surfaces Produced by Intentionally Instable Milling Processes
	4 Surface Structuring Using High-Feed Milling
		4.1 Process Design
		4.2 Simulation Based Process Analysis
		4.3 Analysis of Machined Surface Characteristics
		4.4 Tool Design
		4.5 Post Processing of Structured Surfaces
	5 Conclusion
	Acknowledgment
	References
Amorphous Carbon Coatings for Sheet-Bulk Metal Forming Tools
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Results
		3.1 System Analysis of Forming Processes with Respect to Tribological Behavior
		3.2 Tungsten Modified Amorphous Carbon Coatings with Tailored Properties
			3.2.1 Coating Deposition and Design of Experiments
			3.2.2 Structure and Morphology of a-C:H:W Coatings
			3.2.3 Effects of Process Conditions on Tribological Behavior of a-C:H:W Coatings
			3.2.4 Effects of Process Conditions on Mechanical Properties of a-C:H:W Coatings
			3.2.5 Tailored Mechanical Properties of a-C:H:W Coatings
		3.3 Enhanced Load-Carrying Capacity of Amorphous Carbon Coatings
			3.3.1 Tribological-Mechanical Behavior of a-C:H and a-C:H:W Coatings Under High Contact Loads
			3.3.2 Influence of Multilayered Architectures on Load-Carrying Capacity of Amorphous Carbon Coatings
			3.3.3 Influence of Plasma Nitriding Pretreatments on the Tribological-Mechanical Behavior of Amorphous Carbon Coatings
		3.4 The Role of Amorphous Carbon Coatings on Locally Adapted Tribological Conditions
		3.5 Sensor Coatings
		3.6 Performance of Amorphous Carbon Coatings on Forming Tools
	4 Conclusions and Outlook
	Acknowledgment
	References
Application of Nanostructured Bionic Thin Layers to Enhance the Wear and Friction Behavior of Tools for Sheet-Bulk Metal Forming
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Bionic Structured Tool Surfaces
	4 Modification of the Surface Integrity
	5 Cr-Based PVD Coatings
	6 Application of Tailored Surfaces
	7 Conclusion and Outlook
	Acknowledgement
	References
A 3D Measuring Endoscope for Use in Sheet-Bulk Metal Forming: Design, Algorithms, Applications and Results
	Abstract
	1 Introduction
	2 Motivation
	3 Optical Design
		3.1 Illumination Concepts
			3.1.1 Laser Illumination
			3.1.2 LED Illumination
		3.2 Measuring Heads
	4 Calibration
		4.1 Pinhole Camera Model
		4.2 Lens Distortion
		4.3 Calibration Procedure
	5 Measurement and Masking Process
		5.1 Temporal Carrier Signal and Phase Unwrapping
		5.2 Masking and Outlier Removal
			5.2.1 Signal Based Quality Metrics
			5.2.2 Calibration Based Quality Metrics
	6 Performance and Limits of the Measuring System
		6.1 Measurements on Calibrated Objects
		6.2 Other Factors Affecting the Measurement Uncertainty
	7 Applications
		7.1 In-situ Inspections
			7.1.1 In-situ Inspection Setup
		7.2 Offline Inspections
			7.2.1 Offline Inspection Setup
			7.2.2 Alignment, Registration and Data Processing
			7.2.3 Adaptive Merging
	8 Deviation Calculation and Masking
		8.1 Deviation Calculation
		8.2 Deviation Masking
			8.2.1 CAD-Based Deviation Masking
			8.2.2 Angle-Based Deviation Masking
	9 Results
	10 Conclusion and Outlook
	Acknowledgment
	References
Analysis of Horizontal Loads in Sheet-Bulk Metal Forming and Their Consideration in Simulation
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Characterization of Horizontal Displacements
		3.1 Validation of the Machine Model (Static)
		3.2 Validation of the Machine Model (Dynamic)
	4 Countermeasures to Ram Displacements
		4.1 Design of an Electromagnetic Solenoid System
		4.2 Effects of the Electromagnetic System on the Accuracy of Ram Travel
		4.3 Improvement of Mould Filling by Means of Solenoids
	5 Investigation of Tool Wear
		5.1 Reduction of Tool Wear by Means of Oscillations
	6 A Novel Decoupling Unit to Enable Horizontal Tool Motions
	7 Conclusion and Outlook
	Acknowledgment
	References
Grinding Strategies for Local and Stress Orientated Subsurface Modification of Sheet-Bulk Metal Forming Tools
	Abstract
	1 Introduction
	2 Objective and Methodology
		2.1 Main Influencing Factor of the Grinding Process on the Subsurface Properties
		2.2 Interactions of the Grinding Process on the Subsurface Properties
		2.3 Influence of the Contact Areas on the Subsurface Properties
		2.4 Subsurface Transitions Between Different Machined Tool Areas
		2.5 Influence of the Tool and Dressing Strategies on the Subsurface Properties
	3 Influence of the Process Chain on the Subsurface Properties
		3.1 Coating Pretreatment
	4 Conclusion and Outlook
	Acknowledgment
	References
Constitutive Friction Law for the Description and Optimization of Tailored Surfaces
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Tribology of Sheet Bulk Metal Forming
		3.1 Friction Laws and Numerical Modelling for SBMF
		3.2 Methodology for Experimental Investigation of Friction in SBMF
	4 Tailored Tribological Systems
		4.1 Definition of Requirements for Tailored Tribological Systems
		4.2 Investigation on the Function of Measures to Tailor the Tribological System
		4.3 Investigation on the Functional Stability of Measures to Tailor the Tribological System
		4.4 Synthesis of Results
	5 Conclusion and Outlook
	Acknowledgement
	References
Multilevel Material Modeling to Study Plastic Deformation for Sheet-Bulk Metal Forming Under Different Loading Histories
	Abstract
	1 Introduction
	2 Objective and Methodology
		2.1 Simulation of Polycrystalline Microstructure Under Different Load Histories
		2.2 Plastic Deformation
		2.3 Resolved shear stress
		2.4 Resistance to dislocation movement
		2.5 Evolution of plastic transformation
		2.6 Homogenization
	3 Results
		3.1 Representative Volume Element
		3.2 Development of the effective material model
		3.3 Isotropic hardening
	4 Results
		4.1 Validity of the Macroscopic Model
	5 Conclusion and Outlook
	Acknowledgment
	References
On Optimization Strategies for Inverse Problems in Metalforming
	Abstract
	1 Introduction
	2 Objective/ Methodology
		2.1 Material Modelling
		2.2 Parameter Identification
		2.3 Shape Optimization in the Sense of Non-invasive, Inverse Form Finding
	3 Results and Applications
		3.1 Inverse Parameter Identification
		3.2 Optimization of a Backward Extrusion Process
	4 Conclusion and Outlook
	Acknowledgment
	References
Analysis of Path-Dependent Damage and Microstructure Evolution for Numerical Analysis of Sheet-Bulk Metal Forming Processes
	Abstract
	1 Introduction
	2 Objectives and Methodology
		2.1 Microstructural Characterisation
		2.2 Mechanical Characterisation
		2.3 Constitutive Models and Parameter Identification
		2.4 Acoustic Method
		2.5 Applications
	3 Results
		3.1 Damage Prediction
		3.2 Strain Rate Dependency
	4 Conclusion and Outlook
	Acknowledgment
	References
Fatigue Behavior of Sheet-Bulk Metal Formed Components
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Fatigue Life Modeling Approach
	4 Analysis of Different Material Conditions
		4.1 Ductile Damage in the Different Material Conditions
		4.2 Fatigue Tests and Stress-Strain Behavior
		4.3 Crack Propagation Measurements
		4.4 Fatigue Life Modeling
	5 Fatigue Testing and Modeling the Fatigue Life of SBMF Components
		5.1 Fatigue Testing in a Gear Test Rig
		5.2 Fatigue Testing by Cyclic Loading of a Single Form Element
		5.3 Modeling Fatigue Life of SBMF Components
	6 Discussion
	7 Conclusion and Outlook
	Acknowledgment
	References
Mechanism-Based Modelling of Wear in Sheet-Bulk Metal Forming
	Abstract
	1 Introduction
	2 Objective and Methodology
		2.1 Phenomenological Modelling of Wear
			2.1.1 Continuum Mechanics Basis
			2.1.2 Simulation Framework
		2.2 Towards Mechanism-Based Modelling of Wear
			2.2.1 Simulation of Material Separation with the PFEM
			2.2.2 Contact Modelling with PFEM
			2.2.3 Constitutive Model
			2.2.4 Modelling of Lubrication
	3 Results
		3.1 Phenomenological Modelling of Wear
			3.1.1 Sinusoidal Surface Structures
			3.1.2 Bionic Scarab Beetle Surface Structures
		3.2 Towards Mechanism-Based Modelling of Wear
			3.2.1 Material Separation with PFEM for Notched Plate
			3.2.2 Modelling of Contact with PFEM
			3.2.3 Modelling of Material Separation with PFEM
			3.2.4 Modelling of Lubrication
	4 Conclusion and Outlook
	Acknowledgment
	References
Orbital Forming of Tailored Blanks for Industrial Application
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 State of the Art
		3.1 Process of Orbital Forming
		3.2 Local Short-term Heat Treatment Using Precipitation Modification
	4 Orbital Forming of Tailored Blanks for Industrial Application
		4.1 Manufacturing of Functional Components by Orbital Forming
			4.1.1 Definition of the Demonstrator Geometry
			4.1.2 Experimental Setup
			4.1.3 Experimental Results of Orbital Formed Specimens
		4.2 Lightweight Potential of Precipitation Hardenable Aluminum Alloys
		4.3 Numerical Process Simulation
		4.4 Potential to enlarge the forming limits of orbital forming
			4.4.1 Numerical Potential to Optimize the Die Filling by Extending the Forming Force
			4.4.2 Application of Varying Process Strategies to Enlarge the Forming Limits
			4.4.3 Application of a Local Short-Term Heat Treatment to Enlarge the Forming Limits
	5 Industrial Application
	6 Conclusion and Outlook
	Acknowledgements
	References
Tool Sided Surface Modifications in the Industrial Environment
	Abstract
	1 Introduction
	2 Objective and Methodology of the Research Project
	3 Results
	4 Conclusion and Outlook
	Acknowledgements
	References
Incremental Sheet-Bulk Metal Forming by Application of Thermal-Controlled Grading Mechanisms
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Results
		3.1 Design of the Required Temperature Profile
		3.2 Design of Conductive and Inductive Tools for Forming
		3.3 Experimental Implementation of Thermal Grading in iSBMF
	4 Conclusion and Outlook
	Acknowledgements
	References
Superimposed Oscillation
	Abstract
	1 Introduction
	2 Objective and Methodology
		2.1 Methodology
		2.2 Materials and Methods
		2.3 Experimental Setup
			2.3.1 Tool System
			2.3.2 Industrial Reference Geometry
	3 Results
		3.1 Influencing the Forming Force and Process Time
		3.2 Influencing the Form-Filling
		3.3 Influencing the Surface Quality
	4 Conclusion and Outlook
	Acknowledgment
	References
Numerical Calculation of Tool Wear in Industrial Cold Forming Processes Using the Further Development of Wear Modelling
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Material Characterisation
		3.1 Development of the Tool System
		3.2 Oscillation Superimposed Forming
		3.3 Wear Investigation for the Fischer Process
	4 Conclusion
	5 Outlook
	Acknowledgment
	References
Functionalization of Tool Topographies for Material Flow Control and Tool Life Optimization in Hot Sheet-Bulk Metal Forming – A Concept Study
	Abstract
	1 Introduction
	2 Objective and Methodology
	3 Process Design
		3.1 Machinability of HWS – Thermally Assisted MM
		3.2 Structured Dies in Hot Ring Compression Test
	4 Prototype Tool Under Real Operating Conditions
	5 Achievable Component Quality
	6 Conclusion and Outlook
	Acknowledgment
	References
Fatigue Life Compliant Process Design for the Manufacturing of Cold Die Rolled Components
	Abstract
	1 Introduction
	2 Objective and Methodology
		2.1 Ductile Damage
		2.2 Sample Preparation for Quantification of Ductile Damage
		2.3 Z-Integral Approach and Incremental Step Test
		2.4 Cold Die Rolling Process and Subsequent Heat Treatment
	3 Results
		3.1 Cold Die Forging of the Demonstrator Components
		3.2 Forming-Induced Ductile Damage
		3.3 Residual Stresses After Heat Treatment
		3.4 Fatigue Life Investigation and Modelling
	4 Summary and Outlook
	Acknowledgment
	References
Author Index