SFB 747: Micro Cold Forming - Processes, Characterisation, Optimisation
Computer Science, Systems and Electrical Engineering
Mechanical and Industrial Engineering
Mathematics
Final Report Abstract
The central concern of the Collaborative Research Center "Micro Cold Forming" (SFB 747) of the University of Bremen is the provision of processes and methods for the metal forming of metallic microcomponents. Here lot sizes over 1 million pieces are adressed. The developed processes and methods take into account the special requirements in the micro range resulting from the size effects or use them for innovative approaches. Not only the forming processes themselves, but also the entire process chain from material development, the process steps before and after forming to the planning aspects of micro forming manufacturing were the subject of research. From 2007-2018 more than 60 researchers conducted research on 17 basic projects and 4 transfer projects, the latter being implemented together with industry partners from the accompanying industrial workgroup. With the resulting knowledge of the mechanisms and correlations, a tar- geted process design and connection was made possible for the process-reliable production of metallic components with a size of less than 1 mm and the necessary tools. In order to enable a high speed of innovation in mass production, the methods developed in the SFB are supported simulatively so that rapid product changes are possible. Using simulatively determined process parameters, the micro parts developed in only two steps can be fabricated using the thermal material accumulation developed in the SFB. Rotary swaging was qualified for mass production in the micro range by examining and controlling the technical and material aspects. The influence of the individual deep drawing operations on each other in a two-stage deep drawing process could be identified by tolerance engineering and a prediction of the required tolerances in each process step was possible. A synchronized production, with rates of up to 300 subassemblies / minute was made possible by production in linked parts and a tailor-made conveyor technology made possible. For the integrated planning and evaluation of the complete process chain for the microfabrication, the program μ-ProPlAn was developed and statistical methods for the analysis of interdependencies between production-relevant process parameters and material properties were integrated. Forming tools in mass production must have a long tool life, and be manufactured with high precision due to the small dimensions. Suitable tool materials with favorable tribological properties were qualified for this purpose. The following processes have been developed in the SFB for tool production: The laser chemical removal process (LCM) allows for quality-controlled, flexible processing without significant thermal and microstructural effects for cavities smaller than 200 μm. By optimizing micro-milling, it is possible to produce forming tools and tribologically active surfaces in a single processing step. The process control has been optimized by new mathematical approaches, taking into account the increased speed of innovation. Due to its hardness and tribological properties, diamond is a popular tool material, especially in the micro range. By the introduction of thermo-chemical-mechanical shaping of diamond for micro forming dies, a complex micro structuring of monocrystalline diamonds could be successfully implemented. Progress has also been made in the production and lifetime of graded tool materials (SLM and co-spray). Thanks to the development of a PVD process, hardenable 20 to 30 μm thin films of Al alloys and Al-steel bimetals with good forming properties can be produced, the latter also being continuous and therefore also suitable for mass production. A dropdown furnace was developed especially for micro heat treatment. On the basis of digital holography fast and accurate quality control of micro components could be provided basic and in cooperation with an industrial partner. Characterization methods for the micro range were developed for material testing. In order to be able to carry out comparable measurements, macro standards were also adapted to the micro range.
Publications
- Tribological behavior of micro structured surfaces for micro forming tools. International Journal of Machine Tools and Manufacture 50 4 (2010) 425-430
E. Brinksmeier, O. Riemer, S. Twardy
(See online at https://doi.org/10.1016/j.ijmachtools.2009.11.006) - Classification of laser shock forming within the field of high speed forming processes, Journal of Materials Processing Technology 211 (2011) 953–957
Wielage, H.; Vollertsen, F.
(See online at https://doi.org/10.1016/j.jmatprotec.2010.07.012) - Wear recording at micro deep drawing tools with comparative digital holography, J. Europ. Opt. Soc. Rap. Public 7, 12041 (2012)
Huferath-von Lüpke, S.; Huke, P.; von Kopylow, C.; Bergmann, R. B.
(See online at https://doi.org/10.2971/jeos.2012.12041) - Energy dissipation in laser-based free form heading: a numerical approach, Production Engineering Volume 8, Issue 1-2 (2013) pp 51-61
Jahn, M.; Brüning, H.; Schmidt, A.; Vollertsen, F.
(See online at https://doi.org/10.1007/s11740-013-0509-8) - Micro Metal Forming, Reihe, Lecture Notes in Production Engineering. Springer Berlin (2013)
Vollertsen, F. (Ed.)
(See online at https://doi.org/10.1007/978-3-642-30916-8) - Microstructure and Properties of Selective Laser Melted High Hardness Tool Steel, Lasers in Manufacturing Conference 2013 (LIM2013), Physics Procedia 41 (2013) 843-848
Feuerhahn, F.; Schulz, A.; Seefeld, T.; Vollertsen, F.
(See online at https://doi.org/10.1016/j.phpro.2013.03.157) - Modeling and Simulation of Spray Forming of Clad Deposits with Graded Interface Using Two Scanning Gas Atomizers, Metall. Mater. Trans. B 2013, 44B (4) (2013) 1030-104
Cui, C.; Schulz, A.
(See online at https://doi.org/10.1007/s11663-013-9849-1) - 2D-simulation of material flow during infeed rotary swaging using finite element method, Proc. of the 11th Int. Conf. on Tech. of Plasticity, ICTP 2014, 19-24 October 2014, Nagoya, Japan, Proc. Eng. 81 (2014) 2342 – 2347
Moumi, E.; Ishkina, S.; Kuhfuß, B.; Hochrainer, T.; Struss, A.; Hunkel, M.
(See online at https://doi.org/10.1016/j.proeng.2014.10.331) - FE-sigma - Introducing micro-scale effects into FEM simulation of cold forming, Proceedings from the 5th Int. Conf. on Thermal Process Modeling and Computer Simulation, 16.-18. Juni 2014, Orlando, USA; Ed.: B.L. Ferguson, R. Goldstein and R. Papp, ASM International (2014) 20-25
Lütjens, J.; Hunkel, M.
- Wear behavior in a combined micro blanking and deep drawing process, CIRP Annals Manufacturing Technology 63 (2014) 281-284
Flosky, H.; Vollertsen, F.
(See online at https://doi.org/10.1016/j.cirp.2014.03.125) - Development of micro rotary swaging tools of graded tool steel via co-spray forming, Manufacturing Rev. 2015, 2, 22
Cui, C.; Schulz, A.; Steinbacher, M.; Moumi, E.; Kuhfuß, B.; Böhmermann, F.; Riemer, O.
(See online at https://doi.org/10.1051/mfreview/2015024) - Electrolytes for sustainable laser-chemical machining of titanium, Stellite 21 and tool steel X110CrMoV8-2. Applied Mechanics and Materials, Vol. 794 (2015) 262-269
Hauser, O.; Mehrafsun, S.; Vollertsen, F.
(See online at https://doi.org/10.4028/www.scientific.net/AMM.794.262) - Form filling behavior of preforms generated by laser rod end melting, CIRP Annals - Manufacturing Technology 64 (2015) 293 - 296
Brüning, H.; Vollertsen, F.
(See online at https://doi.org/10.1016/j.cirp.2015.04.129) - Influence of tool geometry variations on the limiting drawing ratio in micro deep drawing, International Journal of Material Forming, Journal no. 12289 (2015) ISSN: 1960-6206 (Print), 1960-6214 (Online)
Behrens, G.; Trier, F. O.; Tetzel, H.; Vollertsen, F.
(See online at https://doi.org/10.1007/s12289-015-1228-9) - Investigation of deformation induced martensitic transformation during incremental forming of 304 stainless steel wires, Proceedings of the 18th International ESAFORM Conference on Material Forming, ESAFORM 2015, 15-17 April 2015, Graz, Austria, Key Eng. Mat. 651-653 (2015) 645-650
Kuhfuß, B.; Moumi, E.; Clausen, B.; Epp, J.; Köhler, B.
(See online at https://doi.org/10.4028/www.scientific.net/KEM.651-653.645) - Least-squares based parameter identification for a function-related surface optimisation in micro ball-end milling, Proceedings of the 15th CIRP Conference on Modelling of Machining Operations (15th CMMO), Procedia CIRP, Volume 31 (2015) 276-281
Vehmeyer, J.; Piotrowska, I.; Böhmermann, F.; Riemer, O.; Maaß, P.
(See online at https://doi.org/10.1016/j.procir.2015.03.076) - On the relation between plasma power and ageing treatment in the production of thin aluminum zirconium foils by magnetron sputtering, Mat.-wiss. u. Werkstofftech. 2016, 47 , No. 11
Egorova, A.; Kovac, J.; von Hehl, A.; Mehner, A.; Zoch, H.-W.
(See online at https://doi.org/10.1002/mawe.201600625) - Performance of a Micro Deep Drawing Die Manufactured by Selective Laser Melting, Proceedings of the 5th International Conference on Nanomanufacturing (nanoMan), 15 – 17 August, 2016, Macau, China (2016)
Flosky, H.; Feuerhahn, F.; Böhmermann, F.; Riemer, O.; Vollertsen, F.
- "Detektion von Anomalien in Bilddaten von Mikrobauteilen“, Industrie 4.0 Management 33 (2017) 52-56
Staar, B., Kück, M., Ait Alla, A., Lütjen, M., Simic, A., Freitag, M.
- Charakteristische Kraftverläufe und resultierende Geometrieabweichungen beim Mikrofräsen von Strukturen in einer Kobalt-Chrom-Legierung. In: Fachbeiträge 8. Kolloquium Mikroproduktion, Bremen, 27.-28. November 2017, Hrsg.: F. Vollertsen, C. Hopmann, V. Schulze, J. Wulfsberg, BIAS Verlag (2017) 155-162 (online) ISBN: 978-3-933762-56-6
Riemer, O.; Elsner-Dörge, F.
- Closed-loop quality control system for laser chemical machining in metal micro production, A. Int J Adv Manuf Technol (2017)
Zhang, P.; von Freyberg, A.; Fischer, A.
(See online at https://doi.org/10.1007/s00170-017-0436-5) - Konditionierung von Halbzeugen durch Mikrorundkneten, In: Fachbeiträge 8. Kolloquium Mikroproduktion, Bremen, 27.-28. November 2017, Hrsg.: F. Vollertsen, C. Hopmann, V. Schulze, J. Wulfsberg, BIAS Verlag (2017) 99-106 (online), ISBN: 978-3-933762-56-6
Ishkina, S.; Schenck, C.; Herrmann, M.; Kuhfuß, B.
- Linked Micro Parts Referencing System, Journal of Mechanics Engineering and Automation 7 (2017) 44-49
Wilhelmi, P.; Schenck, C.; Kuhfuß, B.
(See online at https://doi.org/10.17265/2159-5275/2017.01.006) - Local Characterisation of Variances for the Planning and Configuration of Process Chains in Micro Manufacturing. In: Journal of Manufacturing Systems, 43 (2017) 79-87
Rippel, D.; Lütjen, M.; Freitag, M.
(See online at https://doi.org/10.1016/j.jmsy.2017.02.009) - Mikrostrukturierung von monokristallinem Diamant mittels Reibungspolieren, wt Werkstattstechnik online 107 H. 6 (2017) 467-471
Robert, C.; Riemer, O.; Brinksmeier, E.
(See online at https://doi.org/10.37544/1436-4980-2017-06-83) - Modifikation der Oberflächenfeingestalt monokristalliner Diamanten. In: Fachbeiträge 8. Kolloquium Mikroproduktion, Bremen, 27.-28. November 2017, Hrsg.: F. Vollertsen, C. Hopmann, V. Schulze, J. Wulfsberg, BIAS Verlag (2017) 187-194 (online) ISBN: 978-3-933762-56-6
Robert, C.; Messaoudi, H.; Riemer, O.; Brinksmeier, E.; Vollertsen, F.
- Thermal Analysis of Laser Chemical Machining: Part I: Static Irradiation, Materials Sciences and Applications, 8 (2017) 685-707
Messaoudi, H.; Eckert, S.; Vollertsen, F.
(See online at https://doi.org/10.4236/msa.2017.810049) - Untersuchung und Charakterisierung von rundgekneteten Mikrodrähten des Stahls X5CrNi18-10. In: Tagung "Werkstoffprüfung" 2017, 30.11. und 01.12. Berlin, Hrsg.:H. Frenz, J. Langer. Deutscher Verband für Materialforschung und -prüfung e.V. (DVM) Berlin (2017) 141-146
Köhler, B.; Clausen, B.
- ‘‘Spatial multiplexing digital holography for speckle noise reduction in single-shot holographic two-wavelength contouring,’’ Opt. Eng., 56(12), 124101 (2017)
Agour, M.; Klattenhoff, R.; Falldorf, C.and Bergmann, R. B.
(See online at https://doi.org/10.1117/1.OE.56.12.124101) - „In-Line Quality Control of Micro Parts using Digital Holography”, in: Proc. SPIE 10233, Holography: Advances and Modern Trends V, 1023311 (2017)
Simic, A., Freiheit H., Agour, M., Falldorf, C., and Bergmann, R.B.
(See online at https://doi.org/10.1117/12.2265780) - Application of Cause-Effect-Networks for the process planning in laser rod end melting. In: Vollertsen, F. et al. (Hrgs.): MATEC Web of Conferences 190. EDP Sciences, Les Ulis Cedex, 2018, 9 Seiten
Rippel, D.; Schattmann, C.; Jahn, M.; Lütjen, M.; Schmidt A.
(See online at https://doi.org/10.1051/matecconf/201819015005) - Chances and Limitations in the Application of Laser Chemical Machining for the Manufacture of Micro Forming Dies, 5th International Conference on New Forming Technology (ICNFT 2018), eds.: F. Vollertsen, T.A. Dean, Y. Qin and S.J. Yuan. MATEC Web Conf. 190 15010 (2018)
Messaoudi, H.; Böhmermann, F.; Mikulewitsch, M.; von Freyberg, A.; Fischer, A.; Riemer, O.; Vollertsen, F.
(See online at https://doi.org/10.1051/matecconf/201819015010) - Fast Quality Inspection of Micro Cold Formed Parts using Telecentric Digital Holographic Microscopy, 5th Int.Conf. on New Forming Technology (ICNFT 2018), eds.: F. Vollertsen, T.A. Dean, Y. Qin and S.J. Yuan. MATEC Web Conf. 190 15008 (2018)
Agour, M.; Falldorf, C.; Staar, B.; von Freyberg, A.; Fischer, A.; Lütjen, M.; Bergmann, R. B.
(See online at https://doi.org/10.1051/matecconf/201819015008) - High productivity micro rotary swaging, MATEC Web Conf. 190 (2018) 15002
Moumi, E.; Schenck, C.; Herrmann, M.; Kuhfuss, B.
(See online at https://doi.org/10.1051/matecconf/201819015002) - Interactions between feed system and process in production of preforms as linked micro parts: 5th International Conference on New Forming Technology (ICNFT 2018), eds.: F. Vollertsen, T.A. Dean, Y. Qin and S.J. Yuan. MATEC Web Conf. 190 15014 (2018)
Wilhelmi, P.; Schattmann, C.; Schenck, C.; Kuhfuss, B.
(See online at https://doi.org/10.1051/matecconf/201819015004) - Inverting Prediction Models in Micro Production for Process Design. In: Vollertsen, F. et al. (Hrgs.): MATEC Web of Conferences 190. EDP Sciences, Les Ulis Cedex, 2018, 7 Seiten
Gralla, P.; Piotrowska-Kurczewski, I.; Rippel, D.; Lütjen, M.; Maaß, P.
(See online at https://doi.org/10.1051/matecconf/201819015007) - Multistage eccentric rotary swaging, HTM J. Heat Treatm. Mat. 73 (2018) 344-351
Toenjes, A.; Ishkina, S.; von Hehl, A.; Schenck, C.; Zoch, H.-W.; Kuhfuss, B.
(See online at https://doi.org/10.3139/105.110372) - Tensile properties and drawability of thin bimetallic aluminum-scandium-zirconium / stainless steel foils and monometallic Al-Sc-Zr fabricated by magnetron sputtering. 5th International Conference on New Forming Technology (ICNFT 2018), MATEC Web of Conferences Vol.190 (2018) 15001
Kovac, J.; Heinrich, L.; Köhler, B.; Mehner, A.; Clausen, B.; Zoch, H. W.
(See online at https://doi.org/10.1051/matecconf/201819015001) - Trend-specific clustering for micro mass production of linked parts CIRP Annals - Manufacturing Technology 67 (2018) 9-12
Tracht, K.; Onken, A.-K.; Gralla, P.; Emad, J.H.; Kipry, N.; Maaß, P.
(See online at https://doi.org/10.1016/j.cirp.2018.04.017) - Cold Micro Metal Forming. Springer, Cham (2019)
F. Vollertsen, S. Friedrich, B. Kuhfuss, P. Maaß, C. Thomy, H.-W. Zoch (Eds.)
(See online at https://doi.org/10.1007/978-3-030-11280-6)
