SPP 1204:  Algorythms for Fast, Material Specific Process-Chain Design and Analysis in Metal Forming

• Subject Area: Materials Science and Engineering ; Mechanical and Industrial Engineering
• Term: from 2006 to 2014
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 13758651

In the Priority Programme operations in the field of metal forming, materials science and mathematics shall be conducted, which include the material oriented modelling of processes. The activities aim at developing fast algorithms for the simulation of processes during the metal forming production and finishing. The possibility of setting up a simulation system for each particular product orientated process shall be established. This system will help to watch, analyse and configure single intermediate production steps or the entire process starting with the solid condition of the material and ending with the final component. The analyses can be done in the direction of the production process or inversely. Concurrently the simulation systems shall be suitable to manage and control the forming devices of the single process steps.
It shall be possible to quickly control the particular product quality, the process stability, the input of material and energy as well as the demand on the plants and its configurations. This aim shall be achieved by appropriate models for the modification of geometric tolerances, surface quality, microstructure and the resulting mechanical and technological properties. These models will be implemented in systems, which shall allow creating and designing materials and products in respect to their application. This will contribute to use the full potential of both - material and product.
The interdisciplinary character of the project will promote knowledge exchange between the differently specialised working groups. This strategy shall help to eliminate the present loss of knowledge, for example at the traditional interfaces between semi-finished product manufacturing and subsequent processing and component performance respectively.

• DFG Programme: Priority Programmes
• International Connection: Belgium

Projects

• Entwicklung eines Prozessmodells zur Online-Optimierung von Freiformschmiedungen großer Blöcke (Applicant Hirt, Gerhard )
• Entwicklung und schnelle Optimierung von komplexen Mikrostrukturmodellen für die Steuerung von Umformprozessen in realer Zeit unter Nutzung von schnellen Untersuchungsmethoden (Applicants Lehmann, Gunter ;  Rafaja, David )
• Fast, physically-based algorithms for on-line calculations of texture and anisotrophy during fabrication of steel thin sheets (Applicant Raabe, Dierk )
• Koordinierungsaufgaben im Schwerpunktprogramm "Algorithmen zur schnellen, werkstoffgerechten Prozesskettengestaltung und -analyse in der Umformtechnik" (Applicant Kawalla, Rudolf )
• Modellierung und Regelung der Ausformung komplexer Rohrbauteile unter optimierter Nutzung der Martensitbildung bei austenitischen Edelstählen (Applicants Christ, Hans Jürgen ;  Engel, Bernd ;  Weinberg, Kerstin )
• Modellierung und Simulation der anisotropen Werkstoffentwicklung innerhalb der Prozesskette Kaltwalzen von Bändern und Blechen unter dem Aspekt der Prozeßoptimierung und online - Steuerung (Applicants Ernst, Ph.D., Oliver ;  Kawalla, Rudolf ;  Seefeldt, Marc )
• Simulation, Optimierung und Regelung von Gefügebildung und mechanischen Eigenschaften beim Warmwalzen von Mehrphasenstählen (Applicants Bleck, Wolfgang ;  Hömberg, Dietmar )
• Simulationssystem zur schnellen Analyse des mehrstufigen Warmwalzens von Band und Stabstahl-Draht (Applicant Kawalla, Rudolf )
• Transfer eines Prozessmodells zur Online-Optimierung von Freiformschmiedungen großer Blöcke (Applicant Hirt, Gerhard )
• Zeiteffiziente Prozesskettenmodellierung und -berechnung in der Blechumformung und -verarbeitung (Applicants Schaper, Mirko ;  Svendsen, Robert ;  Tekkaya, A. Erman )

• Spokesperson: Professor Dr.-Ing. Rudolf Kawalla