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A4 - Incremental Forming (funding period 1)

Fundamental research and process development for manufacturing of load optimized parts with incremental forming of thick sheets

Project Status: finished

Last Update: 20.09.2012


The aim of this project is the development of a novel procedure by which load-otimized parts can be produced. For this purpose, cold massive forming methods, as e.g. stamping and rolling, are used. On the one hand, the processes of stamping and rolling (which are shown in the graphic) should lead to a certain material flow and on the other hand the processes should result in in a cold hardening effect. By appropriately combing the processes an accurate definition of these parameters for a wide range of applications might be achieved. Moreover the particular accuracy shall enable calibration processes of preformed part structures.

The focus of this project is on the forming of secondary form elements, like e.g. sprocket structures. Therefore, an investigation of the different processes focusing on the corresponding forces and demands on the machines as well as of the possible precise adjustment of the material flow and of the hardening effect needs to be carried out. Furthermore, the combination of the processes is shall be investigated in more detail.


Working Groups



    • Weckenmann, A.; Reithmeier, E.; Merklein, M.; Wartzack, S.; Behrens, B.; Akkasoglu, G.; Ohrt, C.; Schneider, T.; Salfeld, V.; Breitsprecher, T.; Plugge, B.: Methodengestützte Referenzvorgehensweise für neue Umformverfahren. In: Zeitschrift für wirtschaftlichen Fabrikbetrieb ZWF, 107(2012)1, München: Hanser, pp. 43-47
    • Sieczkarek, P.; Kwiatkowski, L.; Tekkaya, A.; Krebs, E.; Biermann, D.; Tillmann, W.; Herper, J.: Improved Tool Surfaces for Incremental Bulk Forming Processes of Sheet Metals. In: Key Engineering Materials (Edt.): 504(2012), pp. 975-980
    • Sieczkarek, P.; Kwiatkowski, L.; Tekkaya, A.: Blechumformen läuft jetzt ab Losgröße 1. In: VDI (Edt.): VDI Nachrichten, 33(2012), pp. 17


    • Merklein, M.; Tekkaya, A.; Brosius, A.; Opel, S.; Kwiatkowski, L.; Plugge, B.; Schunck, S.: Machines and Tools for Sheet-Bulk Metal Forming. In: Key Engineering Materials, 473(2011), Schweiz: Trans Tech Publications, pp. 91-98
    • Plugge, B.; Kwiatkowski, L.; Brosius, A.; Tekkaya, A.: Untersuchung von Umformstrategien zum Einstellen mechanischer Eigenschaften von Werkstücken mittels inkrementellem Blech-Massiv Walzen (2011), Belfast, pp. 193-200
    • Soyarslan, C.; Plugge, B.; Faßmann, D.; Isik, K.; Kwiatkowski, L.; Schaper, M.; Brosius, A.; Tekkaya, A.: An experimental and Numerical Assessment of Sheet-Bulk Formability of Mild Steel DC04. In: Journal of Manufacturing Science and Engineering, 133(2011)6, pp. 1-9
    • 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
    • Brosius, A.; Soyarslan, C.; Stiemer, M.; Isik, K.; Faßmann, D.; Sieczkarek, P.; Tekkaya, A.; Blum, H.; Schaper, M.; Bach, F.: Numerische und metallurgische Analyse der Werkstoffschädigung in der Blechmassivumformung. In: M. Merklein, Fr.-W. Bach, A.E. Tekkaya (Edt.): Tagungsband zum 1. Workshop Blechmassivumformung, (2011), Bamberg: Meisenbach, pp. 33-50



      • 14.03.2012: Sieczkarek, P.; Kwiatkowski, L.; Tekkaya, A.; Krebs, E.; Biermann, D.; Tillmann, W.; Herper, J.: Improved tool surfaces for incremental bulk forming processes of sheet metals, ESAFORM Conference 2012, Erlangen, Germany


      • 27.04.2011: Plugge, B.; Schunck, S.; Kwiatkowski, L.; Brosius, A.; Tekkaya, A.: Investigation of Forming Strategies to Set up Mechanical Properties of Parts Made by Incremental Sheet Bulk Rolling, ESAFORM Conference 2011, Belfast UK