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A4 - Incremental Forming

Fundamental Research and Process Development for the Manufacturing of Load-Optimized Parts by Incremental Sheet-Bulk Metal Forming

Project Status: Active

Last Update: 02.07.2019


The superordinate aim in the subproject (SP) A4 is the flexible production of near net shaped and load-adjusted functional components by means of incremental sheet bulk metal forming (ISBMF). In the second funding period, this technology has been made use of by means of analytical, numerical and experimental investigations to describe and control the material flow. The identified mechanisms of action thus form an efficient instrument for the geometrical component gradation. Using the principle of the stress superposition, the process forces during the forming of functional elements could be reduced by up to 30%. However, in the case of high-strength materials, despite this force reduction the tool-loads occurring during the final calibration step reduce the tool-lifetime. Nevertheless, a successful calibration step is imperative to reach the required dimensional tolerances which underlines the need for further strategies for a reduction of the tool loads. To improve the precision of the functional elements after forming, three approaches have already been developed and tested:

  • Geometrical adjustment of the initial sheet geometry
  • Adjustment of the process including a pre-forming step
  • Modification of the tool surface using bionical structures (cooperation with SP B2 and SP B5)

In addition to a further reduction of the process forces, the grading of the components mechanical properties represents the superior aim in the third period. This intends to increase both the lifetime of the workpieces as well as the tool lifetime. Reaching this aims means to answer the following scientific questions:


1. The process strategies developed in the second period allow to manufacture parts with an identical geometry but different strain distribution.

→ Central question WP1: Which maximum strength and its distribution can be reached by a variation of the strain route?


2. The combined forming of multiple layered sheets with different material properties to hybrid components was tested in the second funding period.

→ Central question WP2: How does the forming of hybrid components influence the material flow, the occurring forming forces and the potential of grading the mechanical properties of the functional elements?


3. In previous tests the use of an electrical current through the forming region during the forming process has shown a temporary decrease of the forming force of around 20%.

Central question WP3: Which maximum force reduction can be reached, using an electrical current through the forming region, without a significant reduction of the strain hardening.


The strain route controlled strain hardening as well as the use of hybrid components thus allow to adapt the component's mechanical properties to the stress collective occurring during the later use. However, in the case of the tools, the potential for strength enhancement by an alternative material selection or its conditioning is almost exhausted. Therefore, an adjustment of the stress collective to the given stress limits takes place. In addition to the process aided use of an electrical current in the forming zone, the use of hybrid components gives a further approach to reduce the tool load. An overview of the research content for the third funding period is shown below.


 Aims and methods of the subproject A4 during the third period


Working Groups



    • Wernicke, S.; Gies, S.; Tekkaya, A.: Manufacturing of Hybrid Gears by Incremental Sheet-Bulk Metal Forming. In: Procedia Manufacturing, Volume 27, Pages 152-157 (Edt.): (2019), ELSEVIER, published


    • Sieczkarek, P.; Wernicke, S.; Gies, S.; Tekkaya, A.: Inkrementelle Blechmassivumformung. In: wt Werkstattstechnik online (Edt.): 10(2018), Düsseldorf: Springer-VDI-Verlag GmbH & Co. KG, pp. 679-685
    • Gutknecht, F.; Clausmeyer, T.; Wernicke, S.; Gies, S.; Tekkaya, A.: Vorstellung eines Lastpfadindikators für die Blechmassivumformung. In: 19. RoundTable -Simulating Manufacturing 16.-17. Mai 2018, (2018), Congresszentrum Marburg, published


    • Wernicke, S.; Sieczkarek, P.; Gies, S.; Tekkaya, A.: Vorrichtung und Verfahren zur Randaufdickung eines Werkstückes. In: Deutsche Patentanmeldung - Aktenzeichen: DE 10 2017 011 441 (Edt.): (2017), submitted
    • Sieczkarek, P.; Wernicke, S.; Gies, S.; Tekkaya, A.; Krebs, E.; Wiederkehr, P.; Biermann, D.; Tillmann, W.; Stangier, D.: Improvement strategies for the formfilling in incremental gear forming processes. In: Production Engineering, 11(2017)6, pp. 623-631
    • Sieczkarek, P.; Wernicke, S.; Gies, S.; Tekkaya, A.: Incremental Sheet-Bulk Metal Forming - Overview on the development of a new forming technology. In: 50th ICFG Plenary Meeting, 3-6 September 2017, Shanghai, China, (2017), published
    • Wernicke, S.; Gies, S.; Tekkaya, A.; Ben Khalifa, N.: Herstellung Von Belastungsangepassten Funktionsbauteilen Mittels Inkrementeller Blechmassivumformung. In: 22. Umformtechnisches Kolloquium Hannover – Innovationspotentiale in der Umformtechnik (Edt.): (2017), published



      • 07.11.2018: Wernicke, S.; Gies, S.; Tekkaya, A.: Herstellung hybrider Zahnräder durch inkrementelle Blechmassivumformung, ICAFT/SFU/AutoMetForm 2018, Chemnitz