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Last Update: 14.02.2019

The task of the working group tools consists in coordinating the work, which is connected with experimental investigations of the tool technology. Partial projects from the fields of forming, construction and materials technology as well as machining are involved. In the first funding period, a first joint demonstrator was designed to bring together various technologies within the Transregio. In the second funding period the focus was on the tribological investigations of tailored surfaces. For this purpose, a ring compression test was developed for the BMU process. Furthermore, selected tailored surfaces were analyzed in a pin extrusion test. On the basis of numerous experimental investigations, the limits and possibilities of individual processes could be worked out and a comparability could be achieved. In addition, investigations were carried out with a vibration-superimposed flat-bed test in order to determine the influence of the pressing force on modified surfaces. Improved shaping of secondary forming elements by modifying the tool surfaces by tailored surfaces could also be demonstrated by means of real forming processes, such as reverse flow extrusion as well as in incremental forming technology. In addition, preliminary tests on the wear and run-in behavior of Tailored Surfaces were carried out in the AK Tools under high contact normal stresses.

In the third funding period, it is planned to carry out the wear tests on modified insert tools and thus to represent the many-sided requirements of the different BMU processes. Furthermore, the analysis of the interaction of the production processes from the Transregio with regard to residual stresses is the focus. A varying reinforcement of the forming tools is also to be analyzed. The goal is to be able to set desired and locally residual stresses on real tools despite the many-sided manufacturing steps. Finally, the findings will be presented in a joint demonstrator tool.



Head of Working Group




    • 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
    • Freiburg, D.: Hochvorschubfräsen zur Strukturierung von Werkzeugoberflächen für die Blechmassivumformung. In: Dirk Biermann (Edt.): Schriftenreihe des ISF, (2019)97, Essen: Vulkan Verlag GmbH, pp. 192
    • Merklein, M.; Gröbel, D.; Löffler, M.; Henneberg, J.: Investigation on blasted tool surfaces as a measure for material flow control in sheet-bulk metal forming. In: Manufacturing Review, 6(2019)10, pp. 1-9
    • Henneberg, J.; Lucas, H.; Denkena, B.; Merklein, M.: Investigation on the Tribological Behavior of Tool-sided Tailored Surfaces for Controlling the Material Flow in Sheet-Bulk Metal Forning. In: AIP Conference Proceedings 2113 (Edt.): 170002(2019), 22nd International Conference on Material Forming (ESAFORM 2019), pp. 6
    • Biermann, D.; Meijer, A.; Michel, S.; Jaeger, J.P.: Optimierung zerspanender Prozesse in kleinsten Dimensionen. In: maschinenbau - Das Schweizer Industriemagazin, (2019)5, Zürich: Olympa-Verlag AG, pp. 18-21


    • Meijer, A.; Krebs, E.; Wiederkehr, P.; Biermann, D.: Prediction of Feed-Rate Slowdowns in Precise Micromilling Processes. In: Journal of Manufacturing and Materials Processing, 2(2018)1, doi: 10.3390/jmmp2010019: MDPI, published
    • Löffler, M.; Engel, U.; Willner, K.; Beyer, F.; Merklein, M.: Investigation of the tribolgocal behaviour of microstructures for controlling the material flow in sheet-bulk metal forming. In: CIRP Journal of Manufacturing Science and Technology, 22(2018), pp. 66-75
    • 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
    • Grove, T.; Lucas, H.; Denkena, B.: Residual stresses in grinding of forming tools with toric grinding pins. In: Procedia CIRP, 71(2018), pp. 354-357
    • Freiburg, D.; Aßmuth, R.; Garica, R.; Biermann, D.; Henneberg, J.; Merklein, M.: Adaption of tool surface for sheet-bulk metal forming by means of pressurized air wet abrasive jet machining. In: Production Engineering, (2018), Berlin Heidelberg: Springer, pp. 1 -7
    • Schewe, M.; Menzel, A.: The Particle Finite Element Method for the modelling and simulation of solid body interactions. In: Gesellschaft für Angewandte Mathematik und Mechanik (Edt.): Proceedings in Applied Mathematics and Mechanics, 18(2018)1, Weinheim: Wiley-VCH Verlag, pp. 1-2
    • Biermann, D.; Meijer, A.; Krebs, E.; Michel, S.; Jaeger, J.: Neue Entwicklungen für den produktiven Einsatz von Hartmetallwerkzeugen in kleinsten Dimensionen. In: Herbert Danninger, Lorenz Sigl, Christoph Broeckmann (Edt.): Pulvermetallurgie - Neue Herausforderungen und neue Wege, 34(2018), Dortmund: Heimdall, pp. 135-155
    • Biermann, D.; Meijer, A.; Ott, A.: Präparation von Mikrofräswerkzeugen aus Vollhartmetall mit elastisch gebundenen Schleifkörpern. In: Hans-Werner Hoffmeister, Berend Denkena (Edt.): Jahrbuch Schleifen, Honen, Läppen und Polieren: Verfahren und Maschinen, 65(2018), Essen: Vulkan Verlag, pp. 80-92


    • 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



      • 20.02.2019: Schewe, M.; Menzel, A.: Aspekte der Partikel Finite Elemente Methode in der Anwendung auf Kontaktprobleme,
      • 11.03.2019: Commichau, O.: Untersuchungen strukturierter Werkzeugflächen und der Einfluss auf den Werkzeugverschleiß, Hannover
      • 15.05.2019: Meijer, A.: Mikrozerspanung von gehärtetem Schnellarbeitsstahl, Aachen


      • 21.03.2018: Schewe, M.; Menzel, A.: The Particle Finite Element Method for the modelling and simulation of solid body interactions, München
      • 24.08.2018: Meijer, A.: Mikrozerspanung - Von der Simulation des Materialabtrages bis zur intelligenten Fabrik, Dortmund
      • 28.08.2018: Wiederkehr, P.; Meijer, A.: Mikrozerspanung von bionischen Oberflächenstrukturen zur tribologischen Optimierung von Umformprozessen, Bochum
      • 17.09.2018: Freiburg, D.; Biermann, D.: Simulation-based tool development for structuring of surfaces for sheet bulk metal forming tools, Toyohashi, Japan
      • 20.09.2018: Henneberg, J.: Material flow control in sheet-bulk metal forming processes using blasted tool surfaces, Bremen
      • 23.10.2018: Pilz, F.: Numerical Research of Sheet-Bulk Metal Forming Using a Forward and a Lateral Extrusion Process, ICFG Plenary Meeting 2018, Ohio, USA
      • 07.11.2018: Wernicke, S.; Gies, S.; Tekkaya, A.: Herstellung hybrider Zahnräder durch inkrementelle Blechmassivumformung, ICAFT/SFU/AutoMetForm 2018, Chemnitz
      • 28.11.2018: Meijer, A.: Prozessgestaltung für die Strukturierung von Freiformflächen durch Replikation und Verzerrung von Teilbereichen des NC-Programms, École Normale Supérieure Paris-Saclay, Cachan, FR
      • 29.11.2018: Biermann, D.: Neue Entwicklungen für den produktiven Einsatz von Hartmetallwerkzeugen in kleinsten Dimensionen, Hagen