SPP 2183:  Property-controlled metal forming processes

• Subject Area: Mechanical and Industrial Engineering ; Computer Science, Systems and Electrical Engineering ; Materials Science and Engineering ; Mathematics
• Term: since 2019
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 402694744

Production technology is in transition from automated systems to cyber-physical production systems (CPPS). These systems integrate information and planning systems spatially and temporally into the production facilities and are intended to enable robust and adaptable production. This also requires a rethink in the design of forming processes. Components with high reliability and durability are still mainly produced by forming. Forged high-performance components and formed sheet metal parts have applications in energy and transport technology as well as in vehicle construction, for example. Forming processes have evolved over time and have become increasingly automated. Control technology has mainly been used to control the motion sequences of the forming machines. Forming processes therefore run in a controlled manner and can only react to a limited extent to fluctuations in the workpiece or disturbances. For use in resilient factories of the future, controlled processes must be developed that can adapt to changing conditions. The property control of forming processes is necessary to adjust component properties within specifications and to reduce scrap. The challenge in developing property controlled forming processes lies in the non-linear and distributed effect of the tool on the workpiece. Forming processes must be viewed as temporally and spatially distributed systems in order to understand and control them. For the development of efficient controllers, the forming process must be described mathematically and made accessible for systematic development. This priority programme aims to explore the scientific fundamentals of process-integrated property control of forming processes and to practically test and validate new approaches. The cooperation between forming technology and control technology enables the method-based design of controllable forming systems and the consideration of sensors and actuators in the system design. The first phase of the programme demonstrated that forming processes can be developed specifically for property control. The second phase focused on the development of soft sensors and their integration into control strategies. The third phase focuses on the design of forming processes for property control and the quantitative verification of property control under near-production conditions. The programme aims to go beyond the current state of the art and advance the development of property-controlled forming processes.

• DFG Programme: Priority Programmes
• International Connection: Netherlands

Projects

• Control strategy for flow forming to produce workpieces with defined strain hardening (Applicants Awiszus, Birgit ;  Härtel, Sebastian ;  Kanoun, Olfa )
• Controlled solid-liquid transition during twin-roll casting (Applicants Drossel, Welf-Guntram ;  Prahl, Ulrich )
• Coordination Funds (Applicant Bambach, Markus )
• Coordination Funds (Applicant Bambach, Markus )
• Feedback control of surface properties of cold-rolled semi-finished products by development of a novel control concept based on online-roughness measurements of the strip surface (Applicants Hirt, Gerhard ;  Stemmler, Sebastian )
• Multi-variable control with feedforward control of product properties generated by forming processes - basics and application to stamp hole rolling (Applicants Groche, Peter ;  Schulze, Volker )
• Product property controlled multi-stage hot sheet metal forming (Applicants Meurer, Thomas ;  Tekkaya, A. Erman )
• Property control during spinning of metastable austenites (Applicants Homberg, Werner ;  Trächtler, Ansgar ;  Walther, Frank )
• Property-control in forging on screw presses by energy dosage and local actuators (Applicant Bambach, Markus )
• Property-controlled forging: analysis and experimental validation (Applicants Bambach, Markus ;  Herty, Michael )
• Property-controlled process design of freeform bending considering material properties of the semi-finished product (Applicants Lohmann, Boris ;  Münstermann, Sebastian ;  Volk, Wolfram )
• Thermomechanical ring rolling with predictive property control (Applicants Brosius, Alexander ;  Halle, Thorsten )

• Spokesperson: Professor Dr.-Ing. Markus Bambach