SFB 708:  3D-Surface Engineering of Tools for Sheet Metal Forming - Manufacturing, Modelling, Machining

• Subject Area: Materials Science and Engineering ; Computer Science, Systems and Electrical Engineering ; Mechanical and Industrial Engineering
• Term: from 2007 to 2015
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 16071898

The production of high-strength structural elements made of sheet metals for the automotive and the aerospace industries using forming processes requires the use of highly productive tool systems. On the one hand these tools have to provide a long service life for the forming of high-strength steel sheets in the middle or large-scale production. On the other hand the tools have to feature a high dimensional accuracy and surface quality to achieve a high and consistent component quality. These properties have to be provided by the tools, which generally feature a very complex geometry, even at a large number of forming operations. The development and manufacturing of forming tools is a time-consuming and cost-intensive process. An early tool wear does not only lead to loss of the shape accuracy of the formed components, but with advancing wear also to a machine breakdown. Apart from the exchange of the tools, the rework of faulty shaped sheet metal parts also causes considerable costs. Against this background the optimal design of forming tools, especially with regard to their wear resistance and its shape accuracy is of particular importance. To counteract this problem, the SFB 708 develops and investigates a novel manufacturing methodology for the economical and resource-efficient production of highly wear-resistant tool surfaces for the forming technology based on thermally sprayed near net shape coatings. The novel manufacturing method of the "Augmented 3D Surface Engineering" is characterized by the additional integrated virtual modeling of all manufacturing steps. The purpose of the virtual modeling is the practical connection of a wide range of surface engineering manufacturing techniques consisting of milling, thermal spraying, rolling and grinding to a manufacturing process chain as well as the simulation-based validation of the forming using the resulting tool. Beside the production of high quality tools with a low amount of iteration steps the virtual modeling serves to reduce, or in the ideal case to eliminate trial-and-error experiments. The overall objective of the SFB 708 is the realization of ¿Augmented 3D Surface engineering¿ for the production of coated forming tools. This comprises a variety of sophisticated questions related to the material engineering, the manufacturing, the forming, the mathematical modeling, the simulation and optimization as well as efficient algorithms and data structures, which have to be solved and are the subject of the projects in the SFB 708. To realize this, a special feature of SFBs lies in the interdisciplinary cooperation between engineers and methodologists from the fields of mechanical engineering, mathematics, computer science and statistics at the TU Dortmund.

• DFG Programme: Collaborative Research Centres

Completed projects

• A01 - Modification of an arc spray system for production of fine structured, near net-shape wear resistant coatings on complex surfaces (Project Head Tillmann, Wolfgang )
• A02 - Investigation on the application of near-net-shape coatings on complex surfaces using fine, carbide-based powders in the High Velocity Oxy-Fuel flame spraying process (Project Head Tillmann, Wolfgang )
• A03 - Optimization and texturing of coated tool surfaces by local plastic deformation (Project Head Tekkaya, A. Erman )
• A04 - Efficient simulation of dynamic effects in surface oriented robot processing (Project Head Kuhlenkötter, Bernd )
• A05 - Simulation supported NC-shape grinding as a finishing operation of thermally coated deep drawing tools (Project Heads Biermann, Dirk ;  Blum, Heribert )
• A06 - Robot based die spotting of hard material coatings (Project Heads Hypki, Alfred ;  Kuhlenkötter, Bernd )
• B01 - Geometry processing for the virtual realization of manufacturing processes (Project Heads Müller, Heinrich ;  Turek, Stefan )
• B02 - Five-Axis Milling and Simulation System for the Manufacturing of Free-Formed Dies (Project Head Zabel, Andreas )
• B03 - Diagnostics of spraying processes with fine particles (Project Head Tillmann, Wolfgang )
• B04 - Path planning in dynamic environments (Project Head Müller, Heinrich )
• B06 - Multiscale modeling and simulation of the material behavior of thermal spray coatings (Project Heads Denzer, Ralf ;  Menzel, Andreas )
• B07 - Modelling and numerical simulation of surface coating via thermal spraying (Project Heads Möller, Matthias ;  Turek, Stefan )
• B08 - Adaptive Optimal Control of Variational Inequalities in Computational Mechanics (Project Heads Meyer, Christian ;  Rademacher, Ph.D., Andreas )
• C01 - Development of hybrid deep drawing tools of high wear resistance with an adaptive tool stiffness (Project Head Tekkaya, A. Erman )
• C02 - Determination of mechanical and tribological coating properties (Project Head Selvadurai, Ursula )
• C03 - Strategies for springback compensation (Project Heads Brosius, Alexander ;  Kuhnt, Sonja ;  Tekkaya, A. Erman )
• C04 - Information technology, measuring, and reverse engineering for the optimization of process chains (Project Heads Biermann, Dirk ;  Buchheim, Christoph ;  Surmann, Tobias )
• T01 - Nicht starre Registrierungsmethoden für die Analyse und Kompensation der Rückfederung durch die Optimierung von Blechumformwerkzeugen (Project Heads Biermann, Dirk ;  Buchheim, Christoph )
• Z - Central Administration (Project Head Tillmann, Wolfgang )

• Applicant Institution: Technische Universität Dortmund
• Spokesperson: Professor Dr.-Ing. Wolfgang Tillmann