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TRR 188:  Damage Controlled Forming Processes

Subject Area Mechanical and Industrial Engineering
Construction Engineering and Architecture
Materials Science and Engineering
Term since 2017
Website Homepage
Project identifier Deutsche Forschungsgemeinschaft (DFG) - Project number 278868966
 
In the design and production process of formed components the changes of important physical and technical properties of the material caused by the manufacturing process are already taken into account and these properties are specifically adjusted. This applies, for example, to the strength and residual stresses. Damage, i.e. in particular the process of formation and development of voids, is generally only considered with regard to component failure due to cracks. The paradigm shift propagated by the TRR 188 implying to consider damage already in the design and manufacturing process of formed components offers a great potential to realize components with higher performance (e.g. with regard to fatigue strength or relative stiffness in relation to the components’ mass). In order to achieve this goal and to make it usable e.g. for lightweight construction, an interdisciplinary consortium of scientists working on forming technology, materials science, and materials testing technology as well as mechanics cooperates within the TRR 188. New methods and technologies for controlling and predicting both damage and production-specific component properties are investigated and developed, taking into account metal-physical and rheological relationships.In the first funding period it was shown, based on simplified geometries and processes, that the healing of casting pores can be modeled quantitatively and can also be influenced by the process parameters. It was also possible to control damage in a cold forging process and to clearly prove the positive effects of reduced damage on the performance. The occurrence of new damage in sheet metal forming could be significantly reduced by novel forming methods. These technically usable results were only possible through the simultaneous development of new, efficient methods for damage characterization and new, regularized material models. In the second funding period complex component geometries and process sequences will be investigated in detail. The focus of modeling is on models that quantitatively predict the void surface area fraction and its influence on component performance, e.g. in terms of notched bar impact work and fatigue behavior. Furthermore, the interactions of damage mechanisms with microstructure evolution in hot working (e.g. via recrystallization) and their influence on the performance of hot formed components are investigated. Aims of the third funding period are the experimental and simulative investigation and optimization of the components’ performance along the entire process chain for complex forming processes. The implementation of the paradigm shift, outlined above, contributes to resource efficiency in many ways, e.g. by reducing safety factors through the optimal distribution of damage in formed components.
DFG Programme CRC/Transregios

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Applicant Institution Rheinisch-Westfälische Technische Hochschule Aachen, since 1/2021
Co-Applicant Institution Technische Universität Dortmund
Participating University Karlsruher Institut für Technologie
Spokespersons Professor Dr.-Ing. Gerhard Hirt, from 1/2021 until 6/2023; Professor Dr.-Ing. A. Erman Tekkaya, since 7/2023
 
 

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