Industrial doctoral student successfully completes doctorate at the IUL

A highly successful collaboration with industry reached another climax on March 25, 2021: Mr. Sebastian Heibel passed his oral examination on the topic "Damage and failure behavior of high-strength multiphase steels". The PhD student is an industrial PhD student of Daimler AG at the IUL. His doctorate was supervised by Prof. Tekkaya and Dr. Winfried Nester, Daimler AG.

The public PhD lecture was streamed online and found numerous listeners.

The IUL congratulates very warmly!

New KORESIL project launched: Concepts for the resource-efficient and safe production of lightweight structures

On February 15, 2021, under the direction of Prof. Dr.-Ing. habil. Maik Gude from the Institute of Lightweight Structures and Polymer Technology (ILK) at the TU Dresden, the research and development project "Concepts for the resource-efficient and safe production of lightweight structures (KORESIL)" was launched. The joint project of ILK (Dresden), LWF (Paderborn), IART (Freiberg), iwb (Munich) and IUL (Dortmund) focuses on socio-technical solutions for process chains with closed material cycles. In particular, production aids such as online Life Cycle Assessment (LCA), Augmented Reality (AR) and collaborating robots (cobotics) are the focus of the work, which aims to achieve resource-efficient production of lightweight structures and safe, attractive workplace design.

IUL Keynote presentation of the Techtank Conference 2020 is now availabl

In 2020, the (digital) Techtank conference was hold on the topic of “Flexible Production, with focus on forming and stamping”. In his keynote presentation, Prof. Tekkaya talked about “New Technologies at the IUL” to point out the incredible flexibility in forming.

“Techtank Conference is organised by Techtank in collaboration with the Swedish application center Stamping and Forming Center of Excellence. The Conference has been organized since 2015, and is an annual meeting place for manufacturing and engineering companies, research institutes and other organizations that want to keep up to date with current trends in innovative manufacturing for industrial use, with focus on forming and stamping.” (Source: https://www.techtankconference.se)

Watch the full keynote presentation here:

https://youtu.be/XN2AwvZhSeU

New project on prediction of geometry changes during spring production

On December 1, 2020 the new project “Development of a model to predict geometry changes in spring manufacturing based on plasticity theory considering heat treatment“. The research project is funded by the FSV and the AiF. A virtual kick-off meeting with 30 representatives of the project partners from the spring industry took place on January 28. Based on material characterization and experimental investigations of the elementary process steps of winding, heat treatment and pre-setting, an analytical process model of the entire manufacturing process is being developed in the project. The model is intended to enable the determination of residual stresses and geometry changes during the production of helical compression springs, thus facilitating the currently largely experience-based adjustment of automatic winding machines. In addition, a better understanding of the individual manufacturing steps and their influence on the product properties is to be gained.

Contact: Anna Komodromos M. Sc.

 First doctoral examination at the IUL in 2021

On February 2, 2021, Mr. Sebastian Wernicke's oral doctoral examination took place on the topic of "Incremental sheet-bulk metal forming of load-optimized functional components". The PhD public lecture was streamed online and attracted a large audience. This was the 6th digitally conducted doctoral examination at the IUL.

The IUL would like to cordially congratulate Mr. Wernicke on completing his PhD!

First digital lecture delivered from the experimental area at the IUL

On December 17, 2020, the hall lecture at the IUL was held digitally for the first time. This special lecture is held every winter semester as part of the lectures “Fundamentals in Forming Technology” and “Forming Technologies II” in order to provide students with a practical insight into the experimental area. After a short welcome and introduction to the institute by Prof. Tekkaya, the approximately 100 students attending the Zoom meeting were able to participate in a virtual tour through the hall, while at the same time experiments on four experimental stands were streamed live. IUL staff members conducted experiments on parameter identification, rotary draw bending, incremental sheet forming, and adiabatic blanking. The students had the opportunity to ask questions and comment on what they had seen at any time.

DFG approves second funding period of TRR 188
In the SFB / TRR188 “Damage-Controlled Forming Processes”, research on the paradigm shift in forming technology can be continued until 2024.

The German Research Foundation (DFG) has decided to continue funding the Collaborative Research Center Transregio (TRR) 188. For the second funding period until the end of 2024, 11.4 million euros were approved. As initiator and spokesperson of the Collaborative Research Center, Prof. A. E. Tekkaya will regularly hand over the management to Prof. G. Hirt from the IBF at RWTH Aachen University starting from January 2021. Other institutions involved in the second funding period are the “Max-Planck-Institut für Eisenforschung” in Düsseldorf and the Institute for Applied Materials – Section “Materials and Biomechanics” at KIT in Karlsruhe.

Internal material damage occurs when metal is formed. Under the guiding principle that damage is controllable and not a failure, the CRC/TRR 188 investigates how this affects the product properties. Within the interdisciplinary cooperation between forming technology, materials science, materials testing technology, and mechanics, it is be shown that the product design does not have to take the nominal properties into account, but the actual production-induced product properties, including damage. The aim is to indicate the degree of damage to a component quantitatively, to control it, and to specifically adjust it along the process chain. This enables the manufacture of innovative lightweight products with tailored and guaranteed performance.

CRC/TRR 188

Keynote Speech and Article “Damage in Metal Forming”

Together with Pierre-Olivier Bouchard (MINES ParisTech, France), Stefania Bruschi (University of Padova, Italy) and Cem Tasan (Massachusetts Institute of Technology, USA), A. Erman Tekkaya published the keynote paper “Damage in Metal Forming” in the CIRP Annals. The content was significantly influenced by the findings obtained in TRR 188. The presentation is available here: https://www.youtube.com/watch?v=98WD1SLvLE0.

Article in "Mechanics Research Communications"

This paper presents and validates a new simple mechanical model that allows a predictive estimation of the forming history for innovative high-speed forming processes. In particular, this model allows the evaluation of different pulse loads and material models within seconds without the need for complex finite element simulations.

Hahn, M., Tekkaya, A. E., 2020. A quick model for demonstrating high speed forming capabilities. Mechanics Research Communications (108), 103579.

Contact: Marlon Hahn, M. Sc., Head of Department Non-Conventional Processes

New Project on Press Hardening

Process steps of press hardening: a) rapid conductive heating, b) forming and hardening by tool cooling

On September 1, 2020, the joint project "Analysis of the application potential of roll-clad MnB-Cr steel composites for press hardening", jointly proposed by the IUL and the IBF of RWTH Aachen University and funded by the DFG, started. The project investigates the improvement potential of the press hardening process by the use of roll-clad steel composites. The use of corrosion-resistant stainless steel cover layers should allow high heating rates and short holding times, which are not possible with currently used materials. In addition to the time savings achieved by a faster heating strategy, the project will investigate the possibility of producing load-adapted lightweight components by varying the layer ratios of core and cover layers.

Contact: Markus Stennei M. Sc.