Reducing the stair step effect for dies manufactured by layer-laminated manufacturing by additive and formative post-processing

Funding: German Research Foundation (DFG)
Project: TE 508/82-1
Contact: Hamed Dardaei Joghan M. Sc.

A resource-efficient process chain for the flexible manufacturing of dies for deep drawing processes is to be developed. The corresponding high-volume base body of the die is manufactured fast and cost-efficiently from single sheet layers.

In-Situ Hybridization in Deep Drawing Processes – Thermoplastic Fiber-Metal Sandwich Parts Based on Cast Polyamide 6

Funding German Research Foundation (DFG)
Project BE 5196/4-1
Contact Dipl.-Ing. Thomas Mennecart
Status: Completed

Within the project that was conducted in collaboration with the Karlsruhe Institute of Technology (KIT) hybrid components consisting of sheet metals and a glass fiber-reinforced core were successfully manufactured. The two strategies shown in the figure were developed: deep drawing with thermoplastic resin transfer molding and deep drawing with wet-pressing. In the in-situ hybridization experiments the influence of the fibers on the formability of the blanks was investigated. With finite element simulations it was shown that the fiber friction due to contact has a larger influence on the blank’s formability than the friction due to the form-fit between the imprinted fiber structure and the blank in case of high normal loads. With this knowledge, a process strategy primarily featuring an early injection was derived. To avoid the squeezing out of the matrix during the process, another injection at the end of the forming step should be done. This way, a successful in-situ hybridization is possible. With the former chief engineer Nooman Ben Khalifa being appointed Professor for Production Engineering at Leuphana University of Lüneburg and Helmholtz-Zentrum Geesthacht, the project will be continued in Lüneburg.


Strategies for the in-situ hybridization

Economic Manufacturing of Weight- and Load Adapted Functional Components by Incremental Sheet Bulk Metal Forming

Funding AiF/FOSTA
Project 18663 N/P1064
Contact Dr.-Ing. Peter Sieczkarek
Status Completed
The objective of the research project was the production of industrially relevant functional components by means of incremental sheet-bulk metal forming (iSBMF).

Magnetic Pulse Welding: Targeted Manipulation of Weld Seam Formation

Funding: German Research Foundation (DFG)
Project: TE 508/39-3 (SPP 1640 • Teilprojekt A1)
Contact: Dipl.-Wirt.-Ing. Jörn Lueg-Althoff

Within the scope of the project cooperation with the Institute of Manufacturing Science and Engineering at Technische Universität Dresden, different pulse generators and tool coils are used for magnetic pulse welding (MPW) of aluminum tubes and steel cylinders

Forming of Additively Manufactured Sandwich Sheet Composites with Optimized Core Structures

Funding: German Research Foundation (DFG)
Project: TE 508/50-1
Contact: Stephan Rosenthal M. Sc.

In cooperation with the Institute of Product Engineering of the University of Duisburg-Essen sandwich sheets with optimized core structures for the use in forming technologies are developed and additively manufactured.

Forming by Locally Varying Vaporizing Actuators

Funding: German Research Foundation (DFG)
Project: TE 508/69-1
Contact: Marlon Hahn M.Sc.

A thin metal foil can be vaporized by an intense current generated through a rapid capacitor bank discharge (called vaporizing actuator).

Process Combination of Incremental Sheet Forming and Laser Powder Deposition for Lightweight Manufacturing

Funding: German Research Foundation (DFG)
Project: TE 508/68-1
Contact: Lennart M. Tebaay M. Sc.

The project covers the combination of incremental sheet forming (ISF) and additive manufacturing (AM) by laser powder deposition to produce lightweight products (ISF) with functional elements (AM).

Forming Technologies for Metallic and Hybrid Lightweight Structures for the Use in Electromobility

Funding: BMBF/PTKA, Promotion Platform FOREL 2
Project: 02P16Z011
Contact: Marlon Hahn M. Sc.

In this coordination project in collaboration with TU Dresden (TUD), TU Bergakademie Freiberg, Paderborn University, and the Technical University of Munich, topics dealing with future mobility with regard to the manufacturing of lightweight components and recycling of materials are covered.

Improvement of Product Properties by Selective Induction of Residual Stresses in Incremental Sheet Metal Forming

Funding: German Research Foundation (DFG)
Project: TE 508/67-1 (SPP 2013)
Contact: Fabian Maaß M. Sc.

Within the scope of the project cooperation with the Institute for Materials Science and Technology (Metallic Materials) of TU Berlin the relationship between the forming mechanisms shearing, bending, normal loading, and hydrostatic compression in Single Point Incremental Forming (SPIF) and the resulting residual stress state is analyzed.

Prototyping of Metallic Bipolar Plates by Means of Incremental Micro-Forming

Funding: AiF/FOSTA
Project: 14 EWN/P1247
Contact: Dr.-Ing. Peter Sieczkarek

Fuel cells offer a great potential for electromobility. So far, the production of the functional patterns of bipolar plates is performed by deep drawing or hydroforming in the development stage.