SPP 2013:  The utilization of residual stresses induced by metal forming

• Subject Area: Mechanical and Industrial Engineering ; Materials Science and Engineering
• Term: since 2017
• Website: Homepage
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 313778369

The increased demand for lightweight constructions in industrial productions requires the design, manufacture, and use of application oriented components. Forming manufacturing processes have many advantages over machining processes. Not only are the material utilization and productivity optimized, but also the fiber orientation is adapted to the specific task. This results in increased mechanical characteristics and dynamic strength of formed metal components.However, internal stresses greatly influence the performance of components manufactured by forming procedures. The state of initial stress is mainly responsible for component failure during the manufacturing process as well as during the use of the component afterwards. For this reason, internal stresses are currently considered as a highly unfavorable characteristic, which has a negative impact on a component’s feasibility.Efficient models and experimental testing equipment for operational stability already showed promising results for the potential usefulness of internal stresses. Therefore, the objective of the priority program is to regulate and control internal stresses by utilizing forming technologies in order to achieve a positive impact on relevant characteristics of components manufactured by forming processes.

• DFG Programme: Priority Programmes

Projects

• Characterization and Utilization of Process-Induced Residual Stresses for the Manufacturing of Functional Surfaces by Near-Net-Shape-Blanking Processes (Applicants Stahl, Karsten ;  Volk, Wolfram )
• Control of component properties in rotary swaging process (Applicants Epp, Jérémy ;  Kuhfuß, Bernd )
• Coordination Funds (Applicant Volk, Wolfram )
• Defined inducement of residual stresses via suitable forming operations in order to create bi-stable, metallic tube profiles with a full circle cross section (Applicant Hirt, Gerhard )
• Experimental and numerical modeling and analysis of microstructural residual stresses in hot bulk forming parts under specific cooling (Applicants Behrens, Bernd-Arno ;  Brands, Dominik ;  Schröder, Jörg )
• Experimental characterisation and numerical analysis of increasing fatigue strength by residual stresses for cross rolling parts (Applicants Brosius, Alexander ;  Kästner, Markus )
• Generating residual compressive stresses in wire drawing for manufacturing highly-stressed torsion springs (DruDraZie) (Applicants Bergmann, Markus ;  Kräusel, Verena ;  Reimers, Walter )
• Improvement of product properties by selective induction of residual stresses in incremental sheet metal forming (Applicants Lampke, Thomas ;  Tekkaya, A. Erman )
• Investigation of residual stress-related elementary processes for forged components in the manufacturing and operating phase (Applicants Merklein, Marion ;  Steinmann, Paul )
• Selective induction and stabilization of residual stresses in austenitic disc springs by incremental forming and integrated surface layer treatment (Applicants Buhl, Johannes ;  Walther, Frank )
• Targeted creation of residual stresses by forming of local structures in sheet thickness direction via an embossing process to improve component performance (Applicants Böhlke, Thomas ;  Gibmeier, Jens ;  Liewald, Mathias )
• Targeted Manipulation of Residual Stresses during Cold Forging (Applicants Groche, Peter ;  Oechsner, Matthias )
• Utilizing residual stresses in electrical sheet metal to increase energy efficiency (Applicants Hameyer, Kay ;  Schulz, Michael ;  Volk, Wolfram )

• Spokesperson: Professor Dr.-Ing. Wolfram Volk