Department of Bulk Metal Forming

Head     Dr.-Ing. Oliver Hering

The focus of the department of bulk metal forming lies on the investigation of the processes hot extrusion and cold forging. Fundamental issues as well as innovative processes and process variants are investigated. Basically, the influence of the Bauschinger effect occurring during load reversal as well as the influence of forming-induced damage on the performance of cold forged components is investigated. For the application in sheet-bulk metal forming, the occurrence of cross-hardening in sheet metals with orthogonal strain path changes is investigated. For the prediction of the damage evolution, methods for parameter identification based on experimental microstructure investigations are developed.

The process development aims at lightweight-oriented process designs. The processes composite cold forging and combined deep drawing and cold forging allow for lightweight and load-adapted components to be realized. A research focus in extrusion is the grading of the mechanical properties over the profile cross-section for the production of battery boxes.

Members of the department of bulk metal forming

Composite Cold Forging of Cold Forged Semi-Finished Parts

Funding: German Research Foundation (DFG)
Project: 270149504
Contact: Robin Gitschel M. Sc.

Forward rod extrusion of composite billets consisting of a light metal core and a steel cup allow for the production of lightweight gear shafts while losing only small amounts of torsional and bending stiffness in comparison to a steel-only shaft.

Influence of the Multiaxial Bauschinger Effect in Cold Forging

Funding: German Research Foundation (DFG)
Project: 418815343
Contact: Felix Kolpak M. Sc.

In the DFG-funded project new methods were developed that allow the characterization of anisotropic hardening effects exhibited at large strains (see figure).

Influencing the Evolution of Damage in Cold Extrusion

Funding: German Research Foundation (DFG)
Project: CRC/TRR 188 • Subproject A02
Contact: Dr.-Ing. Oliver Hering

Damage in terms of microscopic voids influences the performance of cold extruded components.

Process for Manufacturing Composite Components by a Combination of Deep Drawing and Cold Forging

Funding: German Research Foundation (DFG)
Project: 289596321
Contact: Johannes Gebhard M. Sc.

The combination of deep drawing and cold forging, the so-called draw-forging process, enables the production of composite components consisting of an aluminum core and a steel shell.

Linear Joining of Profiles with Increased Sealing Requirements

Funding: AiF/Stifterverband Metalle
Project: 21048 N
Contact: Florian Kneuper M. Sc.

In cooperation with the Laboratory of Materials and Joining technology (LWF) at Paderborn University, this project investigates the development and implementation of a novel extrusion concept for the production of profiles with increased sealing requirements for battery housings.

Production of Flange-Shaped Components by Cold Forging of Composite Hot Extruded Semi-Finished Products

Funding: German Research Foundation (DFG)
Project: 404239924
Contact: Patrick Kotzyba M. Sc.

The aim of the project is the development of a process route consisting of composite hot extrusion with tubular reinforcing elements and subsequent cold forging to produce flange-shaped components.

Analysis of Strain Path-Dependent Damage and Microstructure Development for the Numerical Design of Sheet-Bulk Metal Forming Processes

Funding: German Research Foundation (DFG)
Project: CRC/TR 73 • Subproject C4
Contact: Florian Gutknecht M. Sc.

Sheet-Bulk Metal Forming (SBMF) enables the near-net-shape production of components directly from sheet metal.

Model Integration for Process Simulation

Funding: German Research Foundation (DFG)
Project: CRC/TRR 188 • Subproject S01
Contact: Alexander Schowtjak M. Sc.

Numerical simulations are used in order to optimally design forming processes in the CRC/TRR 188.

Shape Prediction and Improvement for Canning of Non-Round Tubes

Funding: ReCIMP
Contact: Dr.-Ing. Till Clausmeyer

Exhaust systems for automobiles are facing increased requirements on utilization of assembly space.