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Current projects

Dynamic process forces

 
Contact:blechumformungifum.uni-hannover.de
Duration:4 years
Funded by:DFG SFB / TR73
Brief description:Based on the results of the second phase of funding, this project focuses on the influence of superimposed oscillating, lubrication type and quantity as well as the deformation degree and rate on the friction and component surface quality within the entire process chain. First, non-oscillating and superimposed oscillating ring upsetting tests are done to transfer the gained knowledge to the new sheet bulk metal forming process. In order to get results on the usage of superimposed oscillating produced components, non-oscillating and oscillating pre-stretched samples are examined to determine the remaining plasticity using the method developed at the IFUM of determination of the failure curves.. Furthermore, the wear of the tools should be numerically investigated with the superimposed oscillating sheet-bulk metal forming process.
 
 

Drop forging of coaxially arranged hybrid semi-finished products

 
Contact:massivumformungifum.uni-hannover.de
Duration:4 years
Funded by:DFG
Brief description:As part of subproject B2, the drop forging of joined, coaxially arranged hybrid semi-finished products made of the material combinations steel-steel and aluminium-steel is being investigated in SFB 1153. The overriding goal is the reliable production of rotationally symmetrical hybrid components through targeted control of the material flow. On the one hand, this is done by designing forming tools that are adapted to the material composites to be formed and, on the other hand, by developing a heating concept for realizing similar flow stresses of the materials involved before forming. After drop forging, the joining zone is characterized and the local and global component qualities are determined by mechanical load tests.
 
 

Determination of plasticity and the resulting component properties of serially arranged hybrid semi-finished extrusion products

 
Contact:massivumformungifum.uni-hannover.de
Duration:4 years
Funded by:DFG
Brief description:The subprojekt B3 of CRC 1153 deals with the extrusion of serially-arranged hybrid semi-finished products to determine the plasticity of different joined mixed semi-finished products under a variety of specific extrusion parameters. Due to the thermo-mechanical process a geometrical and micro structural alteration of the joined zone in the hybrid semi-finished product is expected. The resulting questions concern the plasticity of serially arranged hybrid semi-finished products as well as the impact of the forming process on the joined zone and the resulting mechanical properties.
 
 

Development of areas of formed components with reduced strength through a heating unit

 
Contact:blechumformungifum.uni-hannover.de
Duration:2 years
Funded by:DFG/TFP (18029 N/1)
Brief description:The Objective is to create graded material characteristics for hot press hardened components through a local adaption of the micro structure by using the established technology of two-phase spray cooling . A blank completely heated in the heating unit before being cooled down in specific areas, while other areas are held at constant higher temperatures. This blank is afterwards formed in a cooled hot forming die creatingthe desired locally differentiated component properties due to the diffusion-based, bainitic structural transformation in the cooled-down areas.
 
 

Thermal Form-joining of metal and FRP with isothermal tools

 
Contact:blechumformungifum.uni-hannover.de
Duration:2 years
Funded by:19560N/1
Brief description:This research project aims to develop a one-phase form-joining procedure to form and thermally join structural components without the use of additives with isothermal tools in one single step. The temperature of the forming tool constantly stays under the extracting temperature of the forming component throughout the entire process. This allows the extraction of the component directly prior to the form--joining process and the stiffening of the thermoplast. This bypasses an elaborate and especially slow variothermal process design as well as the hardening of adhesives beforehand. The input of thermal energy required to locally melt the thermoplastic surface in the joining zone is decoupled by pre-heating the metal blanks in the oven.
 
 

Application of air-hardening chrome steels to produce high-strength, thin-walled sheet metal forming parts

 
Contact:blechumformungifum.uni-hannover.de
Duration:2 years
Funded by:EFB/AIF (19412N)
Brief description:To advance lightweight construction in the automotive industry, new structural parts with highest strength and adequate elasticity are required. Therefore, this research project deals with the development of a process chain for warm forming and tempering of thin-walled sheet metal forming parts made of air-hardened and carbon martensitic chrome steels. In addition to the determination of basic process parameters to obtain optimized component parameters, economical aspects were equally taken into account to illustrate the entire potential of this material class.
 
 

Development, numerical design and trial of a self-locking, intramedullary nail for initial application with dogs

 
Contact:femifum.uni-hannover.de
Duration:2 years
Funded by:ZIM
Brief description:The treatment of bone fractures of long hollow bones is usually done with plate osteosynthesis or with intramodular usable nails with cross fixation. However, this weakens the bone due to the needed, additional exposure of the bone, drill holes as well as the nail itself. Therefore, this project develops, numerically designs and tests a self-locking nail for the medical application with dogs.
 
 

Extension of the model of heat release for steel

 
Contact:femifum.uni-hannover.de
Duration:2 years
Funded by:EFB/AiF (19245N)
Brief description:Precise knowledge of the temperature generated during plastic deformation inside of a material is very important especially in the case of a crash as it significantly affects the material behavior. This project develops a material model that describes, develops and implements the dissipate heat energy component in a FE-software-system in order to be able to realistic calculate the material behavior.
 
 

Functionally integrated process technology for prefabrication and component production of FRP-metal-hybrid ProVorPlus

 
Contact:blechumformungifum.uni-hannover.de
Duration:4 years
Funded by:BMBF
Brief description:The core idea of the project ProVorPlus is the production of hybrid components made of fiber-reinforced plastic metal using complex hybrid preforms that are prefabricated from simple FRP and metal blanks in a functionally integrated handling and joining process. Later, in the production process, they are converted to a finished hybrid component with a molding and forming operation. The project is connected to the research campus “Open Hybrid LabFactory e.V.”.
 
 

Examination of mechanical properties of massive formed iron-aluminum-alloys

 
Contact:massivumformungifum.uni-hannover.de
Duration:2 years
Funded by:DFG Normalverfahren
Brief description:The main objective of this research it to fundamentally examine forming procedures for cast iron-aluminum-alloys. Additionally, the alloy system FeAl is tested as a forging material. This is achieved through verification of the mechanical improvement through forming processes at the IFUM in Hannover.
 
 

Acoustic emission analysis for online process monitoring of sheet metal forming processes

 
Contact:blechumformungifum.uni-hannover.de
Duration:2 years
Funded by:DFG
Brief description:Online monitoring of a forming process is a popular new tool in sheet metal forming due to the need to 100% control the components to meet rising quality requirements. This research project develops an online-monitoring method based on the acoustic emission analysis.
 
 

Insertion of functional elements during the warm forming of 22MnB5

 
Contact:blechumformungifum.uni-hannover.de
Duration:2 years
Funded by:EFB/AiF (18483 N/2)
Brief description:During the typically used warming process in the oven, a mask is geometrically adapted and fitted into areas determined to require a higher ductility. The blank is masked while entering the oven and the temperature of the mask is close to room-temperature in the beginning. Due to the thermal capacity and the insulation effect of the masking, the warming of the sheet metal material is locally reduced under the mask which causes a partial austenitisation of the blank in the oven.
 
 

Improved FE-simulation of tempered deep drawing of magnesium-sheet metal material using a realistic modeling of its plasticity in process-relevant conditions

 
Contact:femifum.uni-hannover.de
Duration:2 years
Funded by:DFG
 
 

Joining by upset bulging - process extension to increase joint strength and increase the range of applications

 
Contact:femifum.uni-hannover.de
Duration:2 years
Funded by:EFB/AiF
 
 

Examination of cause-effect relationships between topography, friction and wear of the tribological systems tool-component in hot bulk metal forming

 
Contact:massivumformungifum.uni-hannover.de
Duration:3 years
Funded by:DFG
Brief description:Fundamental knowledge about complex cause-effect relationships of the microstructural surface of forging tools, the friction between tool and component as well as the resulting wear properties of the tool is obtained in this project. The basic research focuses on the influence of differently conditioned surfaces on friction parameters, resulting in varying process forces and different wear properties of hot forging dies.
 
 

Production of powder-metallurgical components with a radially graded material system through segregation

 
Contact:massivumformungifum.uni-hannover.de
Duration:3 years
Funded by:DFG
Brief description:A new procedure to produce powder-metallurgical components with a radially graded material system is examined in this project. Using a vertical vibration of a granular medium, consisting of small and large particles, different segregation conditions can be reached. An agglomeration of larger particles to the surface of the container is called Granular convection. By combining vibration-induced segregation with a rotation movement radial segregation can be reached in a cylindric container.
 
 

Substitution of conventional forging lubrication by using self-lubricating material in sinter forging

 
Contact:massivumformungifum.uni-hannover.de
Duration:3 years
Funded by:DFG
Brief description:The economical forging of many products in largescale production is not possible without well-engineered lubrication technology. The research project “Dry forging” develops and tests a new, alternative method to lubricate material with powder metallurgically produced semi-finished products for cold bulk metal forging.
 
 

IPROM – Innovative process chain to produce bulk metal parts using a new lightweight steel

 
Contact:massivumformungifum.uni-hannover.de
Duration:4 years
Funded by:BMBF
Brief description:Sponsored by the Ministry for Education and Research (BMBF) in the framework of “Research for tomorrows production” Project sponsor: Karlsruhe (PTKA)
 
 

Bulk metal lightweight-construction – Technological extension bulk metal forming

 
Contact:massivumformungifum.uni-hannover.de
Duration:4 years
Funded by:DFG, AiF/FOSTA
 
 

Production of gentelligent sinter components made of metal pulver

 
Contact:massivumformungifum.uni-hannover.de
Duration:3 years
Funded by:DFG, Sonderforschungsbereich 653
Brief description:The sub-project E3 of the Collaborative Research Center 653 “The life-cycle of gentelligent components” aims to physically integrate the reproduction and load information of a sinter components life-cycle into the component itself. Such components are called “gentelligente” components. The term “gentelligent” is a combination of the words “genetic” and “intelligent”. The final goal is to be able to produce gentilligent sinter parts. These components offer the possibility to save tamper-proof data inside themselves. Furthermore, the integrated functional elements allow a supervision of load conditions during the production process. This leads to effective tools against plagiarism and offers possibilities to determine the durability of a component.
 
 

Hot forming of 7xxx-aluminum alloys

 
Contact:blechumformungifum.uni-hannover.de
Duration:2 years
Funded by:EFB/AiF (18944N)
Brief description:Using high-strength aluminum alloys of the 7xxx-series allows an advance of material lightweight construction in the automotive industry. However, these alloys have a restricted ability to be formed at room-temperature. Therefore, a suitable tempered process is needed to produce deep drawn components using alloys of the 7xxx-series which is the focus of this research project. Additionally, the influence of the process on corrosive, mechanical and forming properties is examined.
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Investigation of wear resistance properties of eroded layers in hot forging

 
Contact:massivumformungifum.uni-hannover.de
Duration:3 years
Funded by:DFG
Brief description:Tools for hot bulk metal forming are made using different production methods, the choice of which influences the tool surface layers and consequently the tools behavior during use. One reason for the varying behavior during forging is the induced residual stress profile. The objective of this project is to systematically determine the influence of residual stress induced by the manufacturing process on the wear behavior of the tool.
 
 

Clinching for applications under cyclic thermal and mechanical stress

 
Contact:blechumformungifum.uni-hannover.de
Duration:2 years
Funded by:EFB/AiF (18410 N/1)
Brief description:The mechanical joining process clinching is an established and approved process that has shown advantages over thermal or mechanical joining processes using additional joining parts during experiments. This project focuses on the effects of cyclic thermally and cyclic mechanically stressed clinching points with a temperature level of 400°C to 900°C for later application in the exhaust tract.
 
 

Linear driven hybrid actuators for the forming of complex components

 
Contact:umformmaschinenifum.uni-hannover.de
Duration:2015 -
Funded by:DFG
Brief description:The objective of this research project is to determine the fundamentals of a novel drive concept for presses specifically for the production of small stamped bent components. Thedrive concept is a combination of linear motors and electromagnets.
 
 

Power-split press drive

 
Contact:umformmaschinenifum.uni-hannover.de
Duration:2015 -
Funded by:DFG
Brief description:The objective of this study is a novel drive-system for eccentric presses allowing a freely programmable slide kinematic in combination with a lower price and lower operational costs compared to modern servo presses.
 
 

Electromagnetically feed for round rod and profiles (IGF18863)

 
Contact:umformmaschinenifum.uni-hannover.de
Duration:2015 -
Funded by:VDW
Brief description:Currently, round rods, rolls and profiles are fed using mechanical grippers or roll feeds, which often results in slip and therefore position inaccuracy and surface damage of the components due to mechanical contact. This research project focuses on developing an electro-magnetical feed system in order to address these issues.
 
 

Charakterisierung von Horizontalbelastungen bei der Blechmassivumformung

 
Contact:umformmaschinenifum.uni-hannover.de
Duration:2015 -
Funded by:DFG, Transregio 73
Brief description:[Translate to Englisch:] Ziel dieses Projektes ist die Steigerung der Fertigungsqualität von mittels der Blechmassivumformung herzustellenden Werkstücken durch die Verringerung des Maschineneinflusses auf die Bauteilqualität aufgrund von horizontalen Verlagerungen. Damit einhergehend wird eine Erweiterung des herstellbaren Bauteilspektrums angestrebt.