Wear prediction and characterisation of load-adjusted profiles with secondary design elements within draw bending

• Applicants: Professor Dr.-Ing. Bernd-Arno Behrens; Dr.-Ing. Johanna Uhe
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 507245889

The investigations of the first research period have shown the feasibility of draw bending with integrated heat treatment for the production of load-adapted profile components. The following term aims to investigate the draw bending process regarding the production of variable profile cross-sectional geometries with secondary forming elements. The stiffness of the profiles and thus their application range is to be increased by the application of the secondary design elements. Moreover, the possibility to produce variable profile cross sections and a partial heat treatment makes it possible to produce components with tailored properties. For this purpose, an optimized geometry of the blank is to be developed and analyzed using numerical simulations. In addition, an enhancement of the draw bending machine is also planned for the second application period which will allow the production of complex geometries.For the subsequent industrial implementation, fundamental investigations on tribological contact conditions and wear behavior are of vital importance. An increased wear is expected, particularly in the case of secondary forming elements during hot-forming processes. In addition to the technological and scientific challenges, detailed knowledge about the tool wear during draw bending with integrated heat treatment will be obtained. Based on the experimental results of the first research period, a tool wear model for the draw bending process will be developed. The tool wear has to be defined as a function of the process specific contact pressure, the relative velocities as well as the temperature dependent tool hardness and will be implemented in an FE system. The simulative wear prediction will be validated and used to estimate the tool life of the draw bending tools.

• DFG Programme: Research Grants