Department of Non-Conventional Processes

Head       Marlon Hahn M. Sc.

This research department focuses on technologies that offer advantages over traditional forming operations, such as extended forming limits or an increased production flexibility. These processes are either very new or challenges regarding a wide industrial adoption still exist and should be overcome. Current projects deal, for example, with different high speed processes, joining of hybrid material systems by forming, targeted enhancement of a part’s fatigue strength through adjusted incremental forming as well as with novel applications of additive manufacturing, like the improvement of the prototyping technology of layer-laminated deep drawing tools or the forming of innovative three-dimensional high performance structures (cf. figure background). Within all these research projects, both numerical and analytical methods as well as up-to-date experimental measuring techniques are employed to facilitate a fundamental process understanding. This way, further potentials and scientific questions can be identified. The team consists of eight researchers at present (see figure).

Animated image of the department during the pandemic

Forming of Additively Manufactured Sandwich Sheets with Optimized Core Structures

Funding: German Research Foundation (DFG)
Project: 317137194
Contact: Stephan Rosenthal M. Sc.

In cooperation with the Institute for Product Engineering of the University of Duisburg-Essen additively manufactured sandwich sheet composites with core structures optimized for forming are developed.

Automated Joining and Non-Destructive Testing of Tube-Fitting-Joints (AutoFit)

Funding: BMWi/DLR
Project: 20W1905C
Contact: Florian Weber M. Sc.

The research in this project is designed as a collaborative joint project with the partners PFW Aerospace, Steitz Präzisionstechnik, and Fraunhofer IZFP.

Reducing the Stair Step Effect for Dies Manufactured by Layer-Laminated Manufacturing by Additive and Formative Post-Processing

Funding: German Research Foundation (DFG)
Project: 426515407
Contact: Hamed Dardaei Joghan M. Sc.

The aim of the project is to develop a resource-efficient process chain for the flexible manufacturing of dies for deep drawing processes.

Application and Analysis of Adiabatic Blanking

Funding: German Research Foundation (DFG)
Project: 428780322
Contact: Fabian Schmitz M. Sc.

Due to its high local rate of deformation ( ε ̇≥ 104 s-1) and short process time (t < 2 ms), adiabatic blanking exhibits temperature-induced softening.

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

Funding: German Research Foundation (DFG)
Project: 372803376 (SPP 2013)
Contact: Fabian Maaß M. Sc.

The aim of the second funding period of the priority program is to improve metal component properties through forming-induced residual stresses.

Forming by Locally Varying Vaporizing Actuators

Funding: German Research Foundation (DFG)
Project: 391967465
Contact: Marlon Hahn M. Sc.

Discharging a capacitor bank over an Al foil leads to the foil’s rapid vaporization (called vaporizing actuator) so that the resulting pressure – depending on the actuator placement – can be used for a locally flexible sheet metal forming operation.

Optimized Working Coil Windings for Electromagnetic Forming Employing Additive Manufacturing Techniques

Funding: German Research Foundation (DFG)
Project: 259797904
Contact: Siddhant Prakash Goyal M. Sc.

In collaboration with the Institute of Machine Tools and Factory Management of TU Berlin the final funding period of the project is conducted with the objective of developing hybrid (multi-metallic) additively manufactured coils for the process design for electromagnetic forming.

Fundamental Research and Process Development for the Manufacturing of Load-Optimized Parts by Incremental Forming of Metal Sheets – Incremental Sheet-Bulk Metal Forming (iSBMF)

Funding: German Research Foundation (DFG)
Project: CRC/TR 73 • Subproject A4
Contact: Dr.-Ing. Sebastian Wernicke

The main objective is the manufacturing of geometrically complex components from sheets with integrated functional elements by incremental forming.

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

Funding: German Research Foundation (DFG)
Project: CRC/TR 73 • Subproject T04
Contact: Stephan Rosenthal M. Sc.

A challenge of incremental sheet bulk metal forming is to achieve a uniform edge thickness distribution from the sheet edge to the center of the sheet.