SPP 1676:  Dry Metal Forming - Sustainable Production through Dry Processing in Metal Forming

• Subject Area: Mechanical and Industrial Engineering
• Term: from 2013 to 2020
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 220217456

The process of metal forming already belongs to the most energy-efficient production technologies, due to the high material utilisation. From an economic as well as an ecological point of view, there exists a strong demand to avoid lubricants within metal forming processes. Currently, in all groups of procedures in metal forming, lubricants are applied to reduce friction between work piece and forming tool, to protect semi-finished products and goods against corrosion and to reduce tool load. Within their product life cycle - from production to disposal -, these mostly mineral oil based lubricants have an environmental impact. The central contribution of the Priority Programme is the development of new dry forming processes and to adapt relevant technologies to contribute to the goal of a lubricant-free press plant. Dry metal forming is a process where a work piece leaves the forming tool without the necessity of cleaning or drying before subsequent production steps such as coating or joining processes. The absence of a lubricant as an interlayer between work piece and forming tool results in an intense mechanical interaction between work piece surface and forming tool surface. The main challenge is to control these interactions, even without usage of lubricant. The influences of tribological factors and material properties on the process window are different. Understanding these deducing influences shall enable whether a critical reduction of the process window can be avoided. Focussed on the forming tool, the mechanisms of tool failure are in the foreground. To control the mechanisms of failure behaviour and to make dry forming applicable, an increasing load-bearing capacity of forming tools has to be realised to withstand stresses. This can be achieved by a targeted surface modification or by reducing stresses by process technical measures. The purpose is to implement a stable process by such modifications.

• DFG Programme: Priority Programmes

Projects

• Coordination Funds (Applicant Vollertsen, Frank )
• Dry Deep Drawing of Aluminium for Automotive Production (Applicants Müller, Roland ;  Schubert, Andreas ;  Vollertsen, Frank )
• Dry forming of aluminum alloys: from fundamental material and surface characterization to new tribological systems (Applicants Bräuer, Günter ;  Groche, Peter )
• Dry forming of low alloy steels by direct impact extrusion using a self-lubricating tool coating and structured workpieces (Applicants Bergs, Thomas ;  Bobzin, Kirsten )
• Functionalising of a-C:H tool coatings and homogenization of the aluminum passive layer for the dry forming of aluminum (Applicants Bräuer, Günter ;  Groche, Peter )
• Lubricant-free Forming by Affecting Thermoelectric Currents (Applicant Volk, Wolfram )
• Lubricant free forming with tailored tribological conditions (Applicants Merklein, Marion ;  Schmidt, Michael ;  Tremmel, Stephan )
• Lubricant free forming with tailored tribological conditions (Applicants Merklein, Marion ;  Schmidt, Michael ;  Tremmel, Stephan )
• Lubricant-free tribology concepts for cold extrusion by interaction-reduced coatings and structures (Applicants Hirt, Gerhard ;  Häfner, Constantin Leon ;  Schneider, Ph.D., Jochen M. )
• Micro-structuring and macro-structuring of deep drawing tools for dry forming condition (Applicants Beyer, Eckhard ;  Brosius, Alexander ;  Lasagni, Andrés Fabián )
• Polished diamond coatings for dry tapering of aluminum (Applicant Vollertsen, Frank )
• Potentials of dry rotary swaging (Applicants Kuhfuß, Bernd ;  Riemer, Oltmann ;  Zoch, Hans-Werner )
• Selective thermally oxidized tool surfaces for dry deep drawing (Applicants Behrens, Bernd-Arno ;  Maier, Hans Jürgen )
• Self-lubricating HPPMS-CrAlN-coatings for the use in dry cold forging processes of steel (Applicants Bobzin, Kirsten ;  Klocke, Fritz )
• Surface coating for non-lubricated deep drawing of stainless steel (Applicant Seefeld, Thomas )
• Tribosystems for cold forming processes based on volatile lubricants and laser structured surfaces (Applicants Graf, Thomas ;  Hirth, Thomas ;  Liewald, Mathias )
• Tribosystems for cold forming processes based on volatile lubricants and laser structured surfaces (Applicants Graf, Thomas ;  Liewald, Mathias ;  Tovar, Günter )

• Spokesperson: Professor Dr.-Ing. Frank Vollertsen
• Participating Persons: Professor Dr.-Ing. Bernd-Arno Behrens; Professor Dr.-Ing. Eckhard Beyer; Professorin Dr.-Ing. Kirsten Bobzin; Professor Dr.-Ing. Alexander Brosius; Professor Dr. Günter Bräuer; Professor Dr. Thomas Graf; Professor Dr.-Ing. Peter Groche; Professor Dr.-Ing. Gerhard Hirt; Professor Dr.-Ing. Fritz Klocke; Professor Dr.-Ing. Bernd Kuhfuß; Professor Dr.-Ing. Dirk Landgrebe; Professor Dr.-Ing. Andrés Fabián Lasagni; Professor Dr.-Ing. Mathias Liewald; Professor Dr.-Ing. Hans Jürgen Maier; Professorin Dr.-Ing. Marion Merklein; Professor Dr. Reinhart Poprawe; Dr.-Ing. Oltmann Riemer; Professor Dr.-Ing. Stefan Rosiwal; Professor Dr.-Ing. Michael Schmidt; Professor Jochen M. Schneider, Ph.D.; Professor Dr.-Ing. Andreas Schubert; Dr.-Ing. Thomas Seefeld; Professor Dr. Günter Tovar; Professor Dr.-Ing. Stephan Tremmel; Professor Dr.-Ing. Wolfram Volk; Professor Dr.-Ing. Hans-Werner Zoch