Notch rolling and cyclic bending - Basic investigations for the production of bulk materials with a low aspect ratio out of strip material

• Applicant: Professorin Dr.-Ing. Marion Merklein
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2019
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 419390985

The aim of the second phase of the research project is the fundamental analysis of the interactions of the process steps notched rolling and alternating bending. The focus is on the experimental and numerical investigation of damage and crack development, taking into account a further developed hardening and damage model. The extension of the material model enables a target-oriented numerical analysis of the cause-effect relationships between the damage development and its influencing parameters. For a holistic investigation of the interactions, the parameter space is extended by the process and workpiece parameters process velocity, material grade and sheet thickness. The results will provide comprehensive process knowledge that will allow an improved design of the efficient process chain with regard to notch production and controlled separation of the wire strip. Based on the findings of both project phases, a process window will be derived for parameter definition, taking into account the interactions. In summary, the following sub-goals result:• Development of a more profound understanding of the material and a high-quality numerical model by extending the hardening and damage characterization• Analysis of the influencing parameters process velocity, sheet thickness and material grade • Analysis of the cause-effect relationships between the damage development and its influencing parameters • Derivation of a process window for the targeted definition of the process parameters for controlled notch production and wire strip separation

• DFG Programme: Research Grants