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.

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).

Incremental Sheet-Bulk Metal Forming by Application of Thermally-controlled Grading Mechanisms

Funding German Research Foundation (DFG)
Project SFB/TR 73 • Subproject T04
Contact Stefan Gallus M. Sc.

One problem in incremental sheet-bulk metal forming is that during edgethickening (see Figure a) only the outer blank edge is heavily thickened, while the thickness drops radially towards the middle of the blank.

Magnetic Pulse Welding: Targeted Manipulation of Weld Seam Formation

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

With the third project stage of the DFG Priority Program 1640 (“Joining by Plastic Deformation”), the basic investigations on magnetic pulse welding of tubular joining partners were completed.

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.
Status: Completed

In cooperation with the Institute for Product Engineering of the University of Duisburg-Essen composite sandwich panels with core structures optimized for forming are developed.

Forming by Locally Varying Vaporizing Actuators

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

A thin aluminum 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 aim of this project is the analysis of the process combination of incremental sheet forming (ISF) and laser metal deposition (LMD) with respect to its fundamentals and interactions.

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, TU Bergakademie Freiberg, Paderborn University, and the Technical University of Munich, topics dealing with future mobility are addressed, in particular with a focus on numerical prediction accuracy and lightweight design.

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.

The objective of the project SPP 2013 is the deliberate use of forming-induced residual stresses in metal components.