Leibniz Universität Hannover Faculty Faculty of Mechanical Engineering
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Institute of Forming Technology and Machines
 
Institute for Forming Technology and Forming Machines Research Aktuelle Projekte

Blechumformung

  • HyFiVe - "High volume variant production of plastic-metal hybrid components".
    Within this collaborative research project, a component and process strategy for the large-scale variant production of plastic-metal hybrid components is being developed in cooperation with four industrial companies and three research institutions. The production of a battery housing structure for automotive engineering serves as an application example.
    Year: 2020
    Funding: German Federal Ministry of Education and Research (BMBF)

Massivumformung

  • HoWZu – High performance materials of the future
    Starting on August 1st 2024, the IFUM has begun with the project „HoWZu – High performance materials of the future on. The project is funded by the European Union with the infrastructure fund EFRE as well as by the state of lower saxony.
    Led by: Julius Peddinghaus, M. Sc.
    Year: 2024
    Funding: European Regional Development Fund (ERDF) and State of Lower Saxony
  • Forging of α+ß titanium alloys with steel casing
    Titanium alloy products are currently mainly manufactured by machining. However, this leads to relatively large material losses. An alternative production method is the die forging process, whereby the forged titanium is more durable than the machined workpiece. Isothermal forging, which takes place in an inert gas atmosphere to prevent reactions with gases in the air atmosphere, is state of the art. Isothermal forging is therefore difficult to implement in terms of plant and process technology. The use of a steel capsule around the titanium alloy is intended to enable die forging without a protective gas atmosphere and isothermal forging with a low machining volume in order to ensure wider applicability.
    Year: 2023
    Funding: Deutsche Forschungsgemeinschaft (DFG) - Projektnummer 461918196
  • Transparent AI-supported process modeling in drop forging
    The goal of the project is to optimize a die forging process through the use of an AI data model for process modeling. It addresses the challenge of understanding complex interactions between various process parameters. By means of automated data collection, high-quality data are gathered to train the AI model, which will subsequently be capable of recognizing patterns and making predictions about quality characteristics based on process parameters.
    Year: 2022
    Funding: Deutsche Forschungsgemeinschaft (DFG) – SPP2422
  • Highly heat-resistant tool surface layers by extending the tailored forming technology to hot solid forming tools
    In this transfer project, a forming process chain for the production of hybrid forming tools is to be analyzed and developed. Tailored forming technology is used to provide tools made from hot-working steel as the base material with a highly heat-resistant Inconel surface layer. These should have a high resistance to thermomechanical failure patterns and contribute to a significant increase in the service life of tools in hot forging.
    Year: 2022
    Funding: SFB 1153 – Transferprojekt T03
  • ERProFit - Energy and resource efficient production - Low-oxygen forging through retrofitting existing forging systems
    The focus of the project is to prevent scale formation in the process of hot forging by taking place in a low-oxygen atmosphere, which prevents oxidation of the workpiece surface. This results in enormous potential for CO2 savings along the entire value chain, as no unnecessary loss of material occurs due to the lack of scale. Furthermore, natural resources are conserved through the more efficient use of raw materials.
    Year: 2021
    Funding: BMWi - Bundesministeriums für Wirtschaft und Energie
  • Use of additively manufactured forging dies with contour-adapted internal cooling
    Forging dies are subjected to high stress, which leads to wear and reduced tool life. The thermal tool load is essentially due to the contact of the forging die with the heated parts. As part of this research project, complex internal cooling channels are introduced into forging dies using additive manufacturing processes in order to temper them from the inside and counteract thermal tool damage.
    Year: 2020
    Funding: Förderung: Forschungsvereinigung der Arbeitsgemeinschaft der Eisen und Metall verarbeitenden Industrie e.V. (AVIF) – Fördernummer AVIF A 318
  • Novel combination of processes for the production of titanium aluminide-based components in an oxygen-free atmosphere
    Titanium aluminides (TiAl) are among the oxygen-affinous materials whose structural development and thus physical and technological properties depend heavily on the oxygen content. Due to their high heat resistance and very low density, they have high potential for application in the automotive, aerospace and aerospace industries. However, TiAl is difficult to process due to its brittleness, so that isothermal forging or hot isostatic pressing (HIP), which are complex in terms of process and system technology, are primarily used. Conventional powder metallurgical production, using die pressing and sintering, has so far led to inadequate results in terms of relative density as well as technological and physical properties due to impurities.
    Year: 2020
    Funding: Förderung: Deutsche Forschungsgemeinschaft (DFG) – SFB 1368 - Fördernummer 394563137
  • Determination of the deformation capacity and the resulting component properties during extrusion of serially arranged hybrid semi-finished products
    The subproject B3 deals with the extrusion of friction-welded hybrid semi-finished products made of steel-aluminum, steel-nickel-based alloy and steel-steel. During friction welding, different geometries of the end face are used in order to achieve a force and positive connection in addition to the material connection. Extrusion involves a variation of the extrusion process. To increase the stress caused by forming, a hollow shaft will serve as a demonstrator, which will be manufactured using various extrusion processes.
    Year: 2019
    Funding: Deutsche Forschungsgemeinschaft (DFG) – SFB 1153 – B3 – Fördernummer 252662854

Umformmaschinen

  • Set-up assistance system for transfer presses based on AI
    The research question to be answered as part of the project is whether process data combined with domain-specific knowledge can be processed and used in such a way that the gap between existing modeling approaches and reality can be closed with a measurement data-driven modeling of implicit process relationships using AI-based methods.
    Year: 2023
    Funding: Deutsche Forschungsgemeinschaft (DFG) – SPP2422 (Projektnummer 500936349)

Materialcharakterisierung und Simulation

  • Characterisation and modelling of medium Mn steel for the numerical simulation of hot sheet metal forming processes
    In order to fulfil the increasing requirements in the automotive sector regarding safety, range and CO2 emissions, new lightweight materials must be developed which show an optimal combination of strength and ductility. This research project is focused on the design of a process chain for hot forming of sheet metal components made of a novel medium Mn steel. Compared to established hot-forming steels, it offers process-related advantages such as a lower heating temperature and a lower cooling rate. Besides the identification of basic process parameters for optimised component properties, the focus lies on the characterisation and modelling of the flow, failure and transformation behaviour for the numerical process simulation.
    Year: 2024
    Funding: German Research Foundation (DFG) - Project number 505217238
    Duration: 27 Monate
  • Experimental and numerical modelling and analysis of microstructural residual stresses in hot formed components with targeted cooling
    Highly stressed components found e.g. in drives are manufactured by hot forming due to the resulting strength, reliability and cost effectiveness. Currently manufacturing processes aim to lower the remaining residual stresses since they can lead to early component failure. However, research studies showed that especially residual stresses with a negative sign can improve the component performance. Therefore, the aim of this research project is to induce beneficial compressive residual stresses in component-like samples with targeted cooling of the forming heat. Optimal process parameters are determined using FE simulations and the results are experimentally validated in fatigue tests.
    Year: 2024
    Funding: German Research Foundation (DFG) - Project number 530125423
  • Component variation in the manufacture of hybrid composites by free kinematic forming
    Hybrid lightweight material construction enables new design possibilities for structural components. Free kinematic forming is used to research the best possible combination of different materials under economical production conditions. Moreover, the influence of the component geometry is methodically solved by adapting the tool path and generating a tool geometry for component variants
    Year: 2023
    Funding: German Research Foundation (DFG) - Project number 318620418
  • Universal modelling of material and surface modifications for FEM simulation of drop forging of carbon steels
    In order to improve the quality of numerical predictions of hot forging processes, numerical models taking into account the kinetics of scale formation and scale damage behaviour of steel materials are to be developed. The numerical representation is carried out holistically across the process chain of hot forging. In this way, a contribution can be made in hot forging, taking into account scale formation, microstructure transformation, the tribo-system and scale damage.
    Year: 2022
    Funding: German Research Fundation (DFG) – Project number 316273316
  • Determination of the heat transfer coefficient for the numerical design of compound forging processes
    Composite forging of dissimilar materials poses a challenge with regard to the different forming temperatures of the materials. The temperatures present at the contact surfaces of the semi-finished products have a significant influence on the forming result and the formation of intermetallic phases. This project aims to identify the local temperatures of the semi-finished products and dies by determining realistic heat transfer coefficients under process relevant conditions. Using these, the forming result of the compound forging process can be predicted numerically more accurately.
    Year: 2022
    Funding: German Research Fundation (DFG) – Project number 496068488
    Duration: 2 Jahre
  • FE modelling of the semi-hot forming of 7000 aluminium sheet and prediction of component properties after ageing with ANN.
    The aim of the research project is the numerical modelling of the semi-hot forming (SHF) of 7000 aluminium alloys, taking relevant influences such as the temperature-dependent material flow, strain hardening and failure behaviour as well as friction and heat transfer into account. The influence of a cathodic dip coating (CDC) on the mechanical properties of components, which follows forming and is common in automotive manufacturing, is modelled using artificial neural networks (ANN). As a result, a detailed simulation model will be available to represent the SHF of 7000 aluminium including the consideration of a CDC by means of ANN.
    Year: 2021
    Funding: Funding: Industrielle Gemeinschaftsforschung iGF - Funding number: 21645N
  • Modelling of friction values depending on the point of contact as a function of contact pressure and sliding distance
    Currently, constant friction conditions are assumed for conventional FE simulations. But for hot forging operations, extreme process conditions, such as high contract pressures and long sliding paths, lead to friction conditions that change locally and temporally. Therefore, in this project, a new friction model as well as a test methodology for calibration purpose are developed which, allows realistic lubrication conditions to be taken into account for FE simulations.
    Year: 2021
    Funding: Steel Deformation Research Association (FSV) - IGF Project No. 21648N
  • Improved FE simulation of the shear cutting process by a temperature and strain rate dependent extension of the MMC model
    The process design of shear cutting has so far been carried out by time-consuming and cost-intensive experimental test series. Therefore, the aim of this research project is to improve the finite element (FE) simulation of a shear cutting process, in particular with regard to the representation of the resulting cutting edge geometry. A stress based damage model is extended to take into account strain rate and temperature dependency. Experimental tests were carried out to analyse the material behaviour in a wide process relevant range. For the analysis of the material dependency, different steel materials such as the deep drawing steel DC04 or the stainless steel 1.4301 are investigated. Finally, the numerical results are validated by comparison with experimental shear cutting tests.
    Year: 2021
    Funding: German Research Foundation DFG - Grant No.: BE 1691/133-1 - Project No.: 199808648
  • AgaPolCo - Aggregated Polygon forming based processes for large fuselage components
    The forming of aircraft fuselage components by incremental bending is to be extended to complex structures with slightly spherical geometries. The derived aim is to deepen the understanding of the process by numerical models. Based on the gained knowledge, a concept for the production of spherical fuselage components is to be developed by means of FE simulations as well as suitable metamodeling.
    Year: 2021
    Funding: Investitions- und Förderbank Niedersachsen – Nbank (Antrags-Nr. ZW1-80159743)
  • HyFiVe - "High volume variant production of plastic-metal hybrid components".
    Within this collaborative research project, a component and process strategy for the large-scale variant production of plastic-metal hybrid components is being developed in cooperation with four industrial companies and three research institutions. The production of a battery housing structure for automotive engineering serves as an application example.
    Year: 2020
    Funding: German Federal Ministry of Education and Research (BMBF)
  • Extension of the forming limits during deep drawing by additional force transmission
    The process limits in deep drawing can be extended by introducing an additional force in the bottom of the workpiece. Within this project, the fracture behaviour of two high-strength steels is characterised by means of a stress-based fracture model, which is applied in the deep-drawing simulation to enable a numerical design and optimisation of the process. The aim is to investigate the influence of the additional force on the formation of cracks and to optimise the numerical simulation-based process design.
    Year: 2020
    Funding: German Research Foundation (DFG) - Project number 212270168
  • Form-fit in-mould connection between FRP and a sheet metal insert structured with friction drilled bushings
    The aim of this research project is to develop a form-fit connection between a fibre-plastic composite and a metal insert structured with friction-drilled bushings. Thus, components can be produced by hybrid injection moulding processes that provide a multiaxial loadable material bond and a higher bond strength than conventional through-injection points.
    Year: 2020
    Funding: European Research Association for Sheet Metal Processing e.V. (EFB) and Industrielle Gemeinschaftsforschung (IGF) - Project number 20711N
  • Collaborative Research Centre 1153 "Process chain for the production of hybrid high-performance components through tailored forming"
    The goal of the third funding period in subproject A01 of CRC 1153 is to increase process reliability and enhance the robustness of the tailored forming process chain for the production of hybrid components. To achieve this, the research focuses on process development and modelling are expanded to include the new focus on process monitoring.
    Year: 2019
    Funding: German Research Foundation (DFG) – CRC 1153 TP A1 - Project number 252662854
  • Improved failure characterisation of high-strength steel sheet materials using a new test methodology for shear tensile tests in uniaxial tensile testing machines
    The project aims to develop a new test methodology that will allow improved characterisation of stress-based damage models for high-strength steels. The methodology is based on an inline adjustment of the loading direction to ensure homogeneous stress conditions. Increased accuracy of stress-based damage models and thus realistic process modelling allow full usage of the forming potential of high-strength steel sheet materials.
    Year: 2019
    Funding: German Research Foundation (DFG)- Project number 405334714
  • Fundamental investigations of gradient-dependent nitrided forging tools in hot forging under cyclic thermomechanical loads
    In the field of hot foging, the forging tool components are subject to a complex load collective. This is composed of mechanical, tribological, thermal and chemical stress components. Within the scope of the project, therefore, a modelling technique for the numerical wear calculation of nitrided and heat-treated forging tools is to be elaborated.
    Year: 2019
    Funding: DFG BE 1691/229-1
  • Dry lubrication of rolling contacts by self-regenerative molybdenum oxide coating systems
    The aim of the project is to develop a solid lubricant system based on molybdenum, which is characterised in particular by its self-regenerative lubricating layer. The initial focus will be on characterisation and development of the coating system. Subsequently, the wear behaviour will be determined by life tests and transferred to a FE model.
    Year: 2019
    Funding: German Research Foundation (DFG) - SPP 2074 TP2 - Project number 407673224
  • Collaborative Research Centre 1153 "Process chain for the manufacture of hybrid high-performance components by tailored forming"
    The aim in the second funding period is to further improve the hybrid extrusion process that has been developed. For this purpose, asymmetric profiles made of aluminium and steel are extruded, where the bond strength is particularly challenging. The process knowledge from the coaxial composite extrusion process will be transferred to a new material pairing, titanium and aluminium, to increase the lightweight potential.
    Year: 2019
    Funding: German Research Foundation (DFG) - SFB 1153 TP A1 - Project number 252662854
  • Experimental and numerical modelling and analysis of microstructural residual stresses in hot-formed components with targeted cooling
    The challenge of this exciting project is in the simulation of the complex physical processes in hot-formed components before, during and after forming. A large number of process parameters and state data must be taken into account because mechanical, thermal as well as metallurgical variables influence the residual stress state of the final part. The aim is the targeted adjustment and process-technical utilisation of residual stresses for improved performance to enhance the product life cycle properties.
    Year: 2019
    Funding: German Research Foundation (DFG) - Project number 374871564

Last Change: 27.02.25 Print

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