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A2 - Extrusion (funding period 1)

Manufaction of komplex extruded functional elements on sheets

Project Status: finished

Last Update: 07.12.2009


The objective of this project is to analyze fundamentally and to realize a new class of metal forming processes in which starting from blanks, high-precision shape elements are formed by extrusion. Exemplified by a teeth-forming process, the complex interaction between regions of high and low strains will be investigated by sensitivity analyses based on simulation as well as on experiments. Additionally, the fundamentals for laying out the tooling system will be developed considering the specifics of the process compared to conventional ones.

Working Groups



    • Löffler, M.; Engel, U.; Schulte, R.; Gröbel, D.; Krebs, E.; Freiburg, D.; Biermann, D.; Stangier, D.; Tillmann, W.; Weikert, T.; Wartzack, S.; Tremmel, S.; Lucas, H.; Denkena, B.; Merklein, M.: Tribological measures for controlling material flow in sheet-bulk metal forming. In: Production Engineering, 10(2016), pp. 459-470


    • Gröbel, D.; Hildenbrand, P.; Engel, U.; Merklein, M.: Influence of tailored blanks on forming of cold forged functional elements in a sheet bulk metal forming process. In: Metec, Stahl-Institut VDEh (Edt.): Proceedings METEC & 2nd ESTAT, (2015), published on CD


    • Gröbel, D.; Koch, J.; Vierzigmann, U.; Engel, U.; Merklein, M.: Investigations and approaches on material flow of non-uniform arranged cavities in sheet bulk metal forming processes. In: Procedia Engineering, 81(2014), pp. 401-406


    • Merklein, M.; Opel, S.; Schneider, T.; Koch, J.: Überblick der Blechmassivumformung. In: Umformtechnik, 1(2012)3, Bamberg: Meisenbach, pp. 42-43
    • Vierzigmann, U.; Koch, J.; Merklein, M.; Engel, U.: Material Flow in Sheet-Bulk Metal Forming. In: Key Engineering Materials, 504(2012), Durnten-Zurich: Trans Tech Publications, pp. 1035-1040


    • Merklein, M.; Koch, J.; Opel, S.; Schneider, T.: Fundamental investigations on the material flow at combined sheet and bulk metal forming processes. In: Annals of the CIRP, 1(2011)60, Amsterdam: Elsevier, pp. 283-286
    • Merklein, M.; Tekkaya, A.; Brosius, A.; Opel, S.; Koch, J.: Overview on Sheet-Bulk Metal Forming Processes. In: G. Hirt, A.E. Tekkaya (Edt.): Proceedings ICTP 2011, 10(2011), Aachen, pp. 1109-1114
    • Hetzner, H.; Koch, J.; Tremmel, S.; Wartzack, S.; Merklein, M.: Improved Sheet Bulk Metal Forming Processes by Local Adjustment of Tribological Properties. In: J. Manuf. Sci. Eng, 133(2011)6, pp. 061011
    • Schaper, M.; Lizunkova, Y.; Vucetic, M.; Hetzner, H.; Opel, S.; Schneider, T.; Koch, J.; Plugge, B.: Sheet-bulk metal forming a new process for the production of sheet metal parts with functional components. In: Metallurgical and Mining Industry, 3(2011)7, pp. 53-58
    • Biermann, D.; Merklein, M.; Engel, U.; Tillmann, W.; Surmann, T.; Hense, R.; Herper, J.; Koch, J.; Vierzigmann, U.; Krebs, E.: Umformwerkzeuge in der Blechmassivumformung. In: : Merklein, M.; Bach, Fr.-W.; Tekkaya, A. E.; (Edt.): 1. Workshop Blechmassivumformung, 1(2011)1, Bamberg: Meisenbach, pp. 119-138


    • Merklein, M.; Koch, J.; Schneider, T.; Opel, S.; Vierzigmann, U.: Manufacturing of Complex Functional Components with Variants by Using a new Metal Forming Process – Sheet-Bulk Metal Forming. In: International Journal of Metrial Forming, (2010), Paris: Springer, pp. 347-350


    • Merklein, M.: Manufacturing of complex functional components with variants by using a new sheet metal forming process. In: Ruan, X.-Y. (Hrsg.): Proc. of 42nd ICFG Plenary Meeting(2009), published



      • 13.10.2011: Biermann, D.; Merklein, M.; Tillmann, W.; Engel, U.; Surmann, T.; Hense, R.; Herper, J.; Koch, J.; Krebs, E.; Vierzigmann, U.: Umformwerkzeuge in der Blechmassivumformung, 1. Workshop Blechmassivumformung, Erlangen, Germany


      • 09.04.2010: Schneider, T.: Manufacturing of Complex Functional Components with Variants by Using a New Metal Forming Process – Sheet-Bulk Metal Forming, ESAFORM 2010, Brescia