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C6 - Fatigue Behavior

Fatigue Behavior of Sheet-Bulk Metal Formed Workpieces

Project Status: finished

Last Update: 19.01.2021


C6 – Fatigue behavior

Components manufactured by sheet-bulk metal forming have locally inhomogeneous material properties. Due to the cold forming process, locally varying degrees of deformation occur, resulting in differently hardened areas. An additional consequence of cold forming is the introduction of ductile damage in the form of voids in the microstructure. Investigations of the 2nd funding period on specimens from sheet-bulk metal formed components have shown on the one hand that greater work hardening has a positive influence on the service life. On the other hand, an increase of voids due to cyclic loading and thus a negative influence due to increasing ductile damage could be shown. In addition, residual stresses remain in the workpieces as a result of the forming process. Tensile residual stresses favour crack formation and crack propagation during component use and therefore have a negative effect on the fatigue life of the components.

The described material properties have to be taken into consideration for a component layout with respect to their application, for example, as transmission components. Under the influence of cyclic loads, these properties interact with each other and thus require a lifetime analysis of the sheet-bulk metal formed components under "close to service" conditions, since in uniaxial fatigue experiments these interactions cannot be fully taken into account. For this purpose, fatigue tests in a gear test stand are planned in the 3rd funding period, with which geard components can be tested in use and limit loads can be determined.

Working Groups



    • Besserer, H.; Nürnberger, F.; Maier, H.: Fatigue Behavior of Sheet-Bulk Metal Formed Components. In: Merklein, M.; Tekkaya, A. E.; Behrens, B.-A. (Edt.): Sheet Bulk Metal Forming. Research Results of the TCRC73 2020, (2021), Cham: Springer, pp. 412-433
    • Hinz, L.; Metzner, S.; Müller, P.; Schulte, R.; Besserer, H.; Wackenrohr, S.; Sauer, C.; Kästner, M.; Hausotte, T.; Hübner, S.; Nürnberger, F.; Schleich, B.; Behrens, B.; Wartzack, S.; Merklein, M.; Reithmeier, E.: Fringe Projection Profilometry in Production Metrology: A Multi-Scale Comparison in Sheet-Bulk Metal Forming. In: Steve Vanlanduit (Edt.): 21(2021)7, Basel, Suisse: MDPI Sensors, published


    • Besserer, H.; Herbst, S.; Nürnberger, F.: Ermüdungsprüfung von blechmassivumgeformten Bauteilen. In: Behrens, B.-A. (Edt.): Aktuelle Entwicklungen im Bereich der Umformtechnik; 23. Umformtechnisches Kolloquium Hannover, (2020), Garbsen: TEWISS, pp. 100-104


    • Clausmeyer, T.; Nürnberger, F.; Gutknecht, F.; Isik, K.; Besserer, H.; Gerstein, G.; Wernicke, S.; Schulte, R.; Tekkaya, A.; Maier, H.: Analyse und Modellierung von Schädigung und Versagen in der Blechmassivumformung. In: 4. Workshop Blechmassivumformung : Umformtechnische Herstellung von komplexen Funktionsbauteilen mit Nebenformelementen aus Feinblechen, (2019), FAU University Press, submitted


    • Besserer, H.; Rodman, D.: Micro-Scale Residual Stress Measurement Using Focused Ion Beam Techniques and Digital Image Correlation. In: QDE2018, International Conference on Quenching and Distortion Engineering, 27.11.-29.11.2018, (2018), Nagoya, Japan, pp. 32


    • Besserer, H.; Rodman, D.: Fatigue Behavior of Sheet-Bulk Metal Formed Components. In: Materials Science and Technology 2017, 08.-12.10.2017, (2017), Pittsburgh, pp. 859–864
    • Besserer, H.; Rodman, D.: Ermüdungsverhalten blechmassivumgeformter Bauteile. In: Behrens, B.-A. (Edt.): Innovationspotenziale in der Umformtechnik. 22. Umformtechnisches Kolloquium Hannover, (2017), Garbsen: TEWISS, pp. 221
    • Gerstein, G.; Besserer, H.; Nürnberger, F.; Luis Antonio Barrales-Mora; Lasar S. Shvindlerman; Yuri Estrin; Maier, H.: Formation and growth of voids in dual-phase steel at mircrsocale and nanoscale level. In: Journal of Materials Science, 52(2017), Springer, pp. 4234-4243