Coordination Funds

• Applicant: Professor Dr.-Ing. Markus Bambach
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing ; Automation, Mechatronics, Control Systems, Intelligent Technical Systems, Robotics ; Mechanics ; Measurement Systems ; Metallurgical, Thermal and Thermomechanical Treatment of Materials
• Term: from 2019 to 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 424334216

The production of reliable metallic high-performance components is of central importance for energy and transport systems, mechanical and plant engineering and the infrastructure. Components that require high reliability and durability often necessitate manufacturing by metal forming. Forged high-performance components form the basis of technical innovations in energy and transport systems. Formed sheet metal components combine lightweight construction, crash safety and recyclability in vehicle construction. However, forming processes are predominantly open-loop-controlled processes with respect to product properties, i.e. in the forming process, no measurement of the property-determining microstructure and no feedback on the process settings takes place. This involves numerous disadvantages. If forming processes cannot adjust to fluctuations in the process and in the workpiece properties, long development phases for new materials and products, time-consuming post-processing and the production of scrap must be accepted. Increasing demands on resource efficiency and sustainability require the avoidance of scrap production and reinforce the need for closed-loop property-controlled forming processes, in which product shape and properties are set within predetermined tolerances despite unavoidable fluctuations. The challenges for the development of property-controlled forming processes result from the fact that the effect of the tool on the workpiece is highly non-linear and distributed over time and place. For property-control, forming processes must therefore be understood as spatially distributed and temporally variable systems and examined for their controllability. The priority program 2183 aims to lay the scientific foundations for property-controlled forming processes in close interdisciplinary cooperation between metal forming and materials, measurement and control engineering. For metal forming, the cooperation with control engineering creates the possibility of designing controllable forming systems in a structured way and of taking into account the sensors and actuators required for the property control in the system design. Since the microstructure cannot be observed directly in the entire workpiece during the forming process, materials and measurement engineering must develop robust measurements systems and observers that reliably estimate the microstructural state from measurable variables in dynamic measurements. The collaboration is expected to provide a fundamental insight into the design of resilient, microstructure- and property-controlled forming processes.

• DFG Programme: Priority Programmes
• Subproject of: SPP 2183: Property-controlled metal forming processes