Basics of the design of bifurcated expanded profiles

• Applicant: Professor Dr.-Ing. Peter Groche
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 571543981

The project aims at the reliable prediction and utilization of the limits of continuous expanding process of split profiles. For this purpose, the following research questions must be answered: 1. Under which conditions is the numerical modeling of the process limits by adapted damage models for the process chain linear flow splitting - profile stretching applicable? 2. How can yield profiles with optimum weight-related stiffnesses be found on the basis of the numerical models? 3. Which boundary conditions during continuous expanding process are particularly suitable for the production of topologically optimized expand profiles? The first research question addresses the reliable prediction of the failure limits in the sub-processes linear flow splitting and discontinuous expanding and aims in particular at the identification and use of suitable calibration tests for damage modeling. Based on this, answers to the second research question are sought and verified with numerical investigations of a 3-point bending test. Finally, the third research question focuses on the link between the desired expanded profile geometry and the target-oriented boundary conditions during continuous production.

• DFG Programme: Research Grants