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A1 - Deep Drawing

Process Combination for Manufacturing of Teethed, Thin-walled Functional Components out of Tailored Blanks

Project Status: finished

Last Update: 01.10.2020


The goal of the subproject A1 in the third funding period of the SFB-TR73 is the production of stress-adapted functional components with functional elements on both sides of the frame by means of proceeds of sheet-bulk metal forming using process-comprehensive process strategies. The latter enable a consistent analysis of the whole product development process starting at the forming process up to the behavior of functional components made of recyclable steel materials.

The targeted material pre-distribution which is required for the forming of functional elements is enabled due to the application of tailored blanks. These semi-finished products are manufactured by orbital forming and flexible rolling. The realisation of two-sided functional elements leads to new challenges regarding the axial, radial and tangential control of the material flow. In this context the interaction among two-sided form elements in relation to the position, type and design while the production of tailored blanks has to be analyzed. Furthermore it is pursued to form functional elements during the manufacturing of the tailored blanks which are near-net-shaped by a subsequently deep drawing and upsetting process.

For the targeted design of the components regarding the geometrical and mechanical properties, the fatigue strength has to be investigated. With these results and the information about the component requirements, it should be possible to select a customized process chain. The developed strategies are evaluated comparatively. The aim is a process window for manufacturing two-sided, process adapted tailored blanks for a subsequent forming process.

Another focus of the project is the fundamental scientific investigation of manufacturing functional components out of sheet metal by combined sheet and bulk forming processes. Therefore a single-stage combination of a deep drawing and upsetting operation is set up to manufacture a cup and to upset its wall with ongoing ram stroke. Beside the realization of gear teeth the calibration of pre-forms of features like the open carrier after the deep drawing operation is possible by upsetting. After the use of mild deep drawing steels in the first project phase, high strength dual phase steels were successfully qualified for their application in sheet-bulk metal forming processes.


Working Groups



    • Vogel, M.; Schulte, R.; Kaya, O.; Merklein, M.: Manufacturing of tailored blanks with pre-shaped involute gearings by using a flexible rolling process and its application in a sheet-bulk metal forming process. In: The 13th International Conference on the Technology of Plasticity, (2021), accepted


    • Vogel, M.; Schulte, R.; Hetzel, A.; Lechner, M.; Merklein, M.: Verfahrenskombination zur umformtechnischen Herstellung von verzahnten, dünnwandigen Funktionselementen aus prozessoptimierten Halbzeugen. In: Bernd-Arno Behrens (Edt.): Aktuelle Entwicklungen im Bereich der Umformtechnik - 23. Umformtechnisches Kolloquium Hannover 04. und 05. März 2020, (2020), Hannover: TEWISS, pp. 178


    • Hetzel, A.; Schulte, R.; Degner, J.; Merklein, M.: Maßgeschneiderte Halbzeuge - Umformtechnische Herstellung von Funktionsbauteilen zur Realisierung von Leichtbaukomponenten109(2019)10, Werkstattstechnik online, pp. 745-749
    • Löffler, M.; Schulte, R.; Freiburg, D.; Biermann, D.; Stangier, D.; Tillmann, W.; Merklein, M.: Control of the material flow in sheet-bulk metal forming using modifications of the tool surface. In: International Journal of Material Forming, 12(2019), pp. 17-26
    • Vogel, M.; Schulte, R.; Freiburg, D.; Lechner, M.; Biermann, D.; Merklein, M.: Maßgeschneiderte Werkzeugoberflächen in einem flexibeln Walzprozess. In: M. Merklein, B.-A. Behrens, A. E. Tekkaya (Edt.): 4. Workshop Blechmassivumformung, (2019), FAU University Press, pp. 89-108
    • Vogel, M.; Merklein, M.: Manufacturing of tailored blanks by orbital forming with a two-sided material thickening. In: Journal of Material Processing Technology, (2019), pp. 116491
    • Vogel, M.; Merklein, M.: Flexible rolling of rotational symmetric tailored blanks with a two-sided thickness profile. In: Procedia Manufacturing, (2019), pp. 139-146
    • Schulte, R.; Graser, M.; Merklein, M.: Enhancement of Forming Limits for Aluminum in Sheet-bulk Metal Forming by Local Laser Heat Treatment. In: Yannis Korkolis, Brad Kinsey, Marko Knezevic, and Nikhil Padhye (Edt.): Proceedings of NUMIFORM 2019: The 13th International Conference on Numerical Methods in Industrial Forming Processes, (2019), pp. 333-336
    • Schulte, R.; Merklein, M.: Manufacturing of functional aluminum components by using sheet bulk metal forming processes. In: Dimitrov, Dimiter; Hagedorn-Hansen, Devon; Von Leipzig, Konrad (Edt.): International Conference on Competitive Manufacturing (COMA 19) Proceedings, (2019), pp. 331-336
    • Hildenbrand, P.: Entwicklung einer Methodik zur Herstellung von Tailored Blanks mit definierten Halbzeugeigenschaften durch einen Taumelprozess. In: Jörg Franke, Nico Hanenkamp, Marion Merklein, Michael Schmidt, Sandro Wartzack (Edt.): FAU Studien aus dem Maschinenbau, (2019), Erlangen: FAU University Press, published
    • Schulte, R.; Lechner, M.; Merklein, M.: Fundamental analysis of the application of hybrid semi-finished products in sheet-bulk metal forming. In: 1st International Conference on Advanced Joining Processes AJP 2019, (2019), published on CD


    • Hildenbrand, P.; Lechner, M.; Vogel, M.; Herrmann, H.; Merklein, M.: Orbital forming of tailored blanks with two-sided local material thickening. In: The International Journal of Advanced Manufacturing Technology, 97(2018), pp. 1-10
    • , .; Merklein, M.: Manufacturing of process adapted tailored blanks by a flexible rolling process using the aluminum alloy AA6016. In: Procedia Manufacturing, 15(2018), pp. 1224-1231
    • Vogel, M.; Merklein, M.: Oberflächenanalyse von Tailored Blanks hergestellt durch ein Taumelverfahren. In: Lehrstuhl für Umformtechnik, Montanuniversität Leoben, Bruno Buchmayr (Edt.): XXXVII. Verformungskundliches Kolloquium, (2018), pp. 91-96


    • Kirchen, I.; Vogel-Heuser, B.; Hildenbrand, P.; Schulte, R.; Lechner, M.; Vogel, M.; Merklein, M.: Data-driven Model Development for Quality Prediction in Forming Technology. In: 15th IEEE International Conference on Industrial Informatics (INDIN), (2017), pp. 775-780
    • Schulte, R.; Frey, P.; Hildenbrand, P.; Vogel, M.; Betz, C.; Lechner, M.; Merklein, M.: Data-Based Control of A Multi-Step Forming Process. In: Journal of Physics: Conference Series, (2017), pp. 012037
    • Schulte, R.; Hildenbrand, P.; Vogel, M.; Lechner, M.; Merklein, M.: Analysis of fundamental dependencies between manufacturing and processing Tailored Blanks in sheet-bulk metal forming processes. In: Procedia Engineering, (2017), pp. 305-310
    • Schulte, R.; Lechner, M.; Vogel, M.; Hildenbrand, P.; Merklein, M.: Umformtechnische Herstellung von Funktionsbauteilen aus Tailored Blanks durch Blechmassivumformverfahren. In: 22. Umformtechnisches Kolloquium Hannover – Innovationspotentiale in der Umformtechnik. 15./16.03.2017, (2017), published
    • Vogel, M.; Lechner, M.; Hildenbrand, P.; Schulte, R.; Merklein, M.: Manufacturing of tailored blanks by flexible rolling and its application in a sheet-bulk metal forming process. In: Wieland (Edt.): Proceedings SCT2017, (2017), Verlag Stahleisen GmbH, published on CD
    • Schulte, R.; Hildenbrand, P.; Lechner, M.; Merklein, M.: Designing, manufacturing and processing of Tailored Blanks in a sheet-bulk metal forming process. In: Procedia Manufacturing, (2017), pp. -


    • Schulte, R.; Schneider, T.; Lechner, M.; Merklein, M.: Interaction of various functional elements in thin-walled cups formed by a sheet-bulk metal forming process. In: K. Saanouni (Edt.): NUMIFORM 2016: The 12th International Conference on Numerical Methods in Industrial Forming Processes , MATEC Web Conf. , (2016), pp. 07003