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
Finished projects

Finished research projects at the Institute of Forming Technology and Machines

Sheet metal forming

  • 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)

Bulk metal forming

  • 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

Material characterization and simulation

  • 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
  • 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)
  • 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
  • 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
  • Development of a methodology for fatigue life time assessment of highly loaded hot forming dies based on advanced material models.
    The aim of the project is to develop a concept for computer-aided fatigue life time assessment of hot forming dies. For this purpose, the softening and plastic deformation of the die as a result of cyclic thermomechanical loading are to be taken into account by means of appropriate material models. Thus, a more precise analysis of the cycle-dependent die damage is possible.
    Year: 2020
    Funding: German Research Foundation (DFG) - Project number 244928365
  • 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
  • Experimental as well as numerical modelling and analysis of microstructural residual stresses of hot formed components with targeted cooling
    This project deals with the experimental and numerical investigation of the development of residual stresses in hot forming processes with integrated heat treatment. The overall aim is the targeted modification of the residual stress state in the final component to improve its properties like wear resistance and fatigue strength. Since mechanical as well as thermal and metallurgical material phenomenon influence, the residual stress state the effect of a large number of process parameters and state data must be taken into account.
    Year: 2019
    Funding: German Research Foundation (DFG) - Project number 374871564
  • Integrated process simulation of thermoforming and injection moulding
    The aim of this research project is the development of a simulation model for the improved numerical representation of a combined thermoforming-injection moulding process for the production of hybrid components made of fibre-reinforced plastics (FRP). Here, both processes are coupled in a simulation environment via a direct fluid-structure interaction. This enables the modelling of the composite strength as a function of the process parameters temperature, pressure and contact time. The validation of the simulation model for the determination of the bond strength is carried out using a practice-relevant example process.
    Year: 2019
    Funding: European Research Association for Sheet Metal Processing (EFB) Industrielle Gemeinschaftsforschung (IGF) - Project number 20524 N/2
  • The Numerical calculation of tool wear in industrial cold forging processes through further developments of the modelling of wear
    This project aims to transfer the knowledge gained in the sub-project (SP) A7 of the transregional collaborative research Centre (TCRC) 73 to processes under industrial conditions. For this, the advantages of superimposed oscillations, as well as the further development and validation of numerical wear modelling is applied to a cold forging processes with high contact normal stresses. The production tests of sheet metal forming in SP B7 will serve as a basis for the wear investigation. In this project, both numerical and experimental investigations will be carried out on a demonstrator process, which is derived from a complex multi-stage cold forging process of the company Fischer. For the adaptation to the industrial process, the wear model will be extended and validated by including industrial tool service lives from the processes of the company Fischerwerke GmbH & Co.
    Year: 2019
    Funding: German Research Foundation (DFG) - SFB TR-73 - Project number 417860413
  • 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
  • : Patient-adaptive pressure monitoring and treatment system for glaucoma therapy
    In collaboration with various institutes of Leibniz Universität Hannover (LUH), Hannover Medical School (MHH), and two medical technology companies, this research project aims to develop a pressure treatment system intended to enhance the therapy of the ocular disease "glaucoma." This system will facilitate timely intervention by an ophthalmologist in the event of hypertension. Such proactive management is crucial in preventing the insidious threat of unnoticed elevated pressure, which can result in the damage or death of the optic nerves.
    Year: 2018
    Funding: Central Innovation Programme for SMEs (ZIM) - Project number ZF4332302AW8
  • Approach for the numerical determination of the hardness evolution in the tool surface layer due to thermal loads during press hardening
    For industrial companies in the metalworking sector, knowledge of the wear properties of the used tools during the process time is very important. Therefore a methodology for the improvement of hardness development prediction for thermally high loaded dies will be developed, which will allow a better planning of tool set-up times and thus a cost reduction.
    Year: 2018
    Funding: Forschungsvereinigung Stahlanwendung e. V. (FOSTA) Industrielle Gemeinschaftsforschung (IGF) - Funding number 19518 N
  • Determination of the forming limits of martensitic chromium steels in hot sheet forming
    The aim of this research project is to model the hot forming of martensitic chromium steel AISI420 numerically, taking into account its forming limit at elevated temperatures, the microstructural transformations taking place and their effects on the resulting component properties.
    Year: 2018
    Funding: German Research Foundation (DFG) - Project number 385989694
  • Development of a test methodology to determine the re-hardening and tempering effects of forging tools under cyclic thermomechanical loading to improve numerical wear prediction
    In hot forging, a realistic numerical description of die hardness development as a result of cyclic thermo-mechanical loading leads to an increase in the accuracy of wear prediction. Improved knowledge of local wear development enables the optimisation of tool service life and an improvement in process planning. This ultimately serves the continuous and reliable production of high-quality components as well as the more accurate prediction of the necessary tool change times.
    Year: 2017
    Funding: Industrieverband Massivumformung e. V. (IMU) Industrielle Gemeinschaftsforschung (IGF) – Fördernummer 19647 N
  • Numerical calculation of thermal load and tool life in thixoforming of steel
    The aim of this project is the simulation-based prediction of the tool life in thixoforming processes under consideration of cyclic thermomechanical loading. The focus is on the numerical representation of the thermomechanical induced crack formation in the tool by parameterisation and implementation of the damage model according to Sehitoglu. Finally, measures to increase the tool life can be derived from the numerical calculation of the tool life.
    Year: 2017
    Funding: German Research Foundation (DFG) - Project number 299534929
  • Mobility in Science and Engineering
    The research line "Mobilise" addresses challenges in mobility-related sciences, especially in the focus areas of digitalisation, energy transition in aviation as well as production and lightweight construction. Through a long-term cooperation of the participating universities Technische Universität Braunschweig (TUBS) and Leibniz Universität Hannover (LUH), existing research competencies are strengthened, their complementary further development is promoted and the networking of researchers is supported.
    Year: 2017
    Funding: Ministry of Science and Culture of Lower Saxony (MWK) PL-1
  • Improved FE simulation of tempered deep drawing in magnesium sheet materials through realistic modelling of their deformation capacity under process-relevant conditions
    Magnesium alloys offer a high potential for lightweight constructions. To increase the accuracy of its numerical process design, the specific temperature-dependent material behaviour of a magnesium sheet alloy is to be characterised and modelled in the project. Furthermore, it is intended to describe the failure behaviour with the help of a suitable stress-based failure mode, so possible failure states of deep-drawn components outside the range of validity of a forming limit curve (FLC) could be predicted under consideration of elevated forming temperatures.
    Year: 2016
    Funding: German Research Foundation (DFG) - Project number 44192561

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