Control strategy for flow forming to produce workpieces with defined strain hardening

• Applicants: Professorin Dr.-Ing. Birgit Awiszus; Professor Dr.-Ing. Sebastian Härtel; Professorin Dr.-Ing. Olfa Kanoun
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2019
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 424334154

The overall objective of the project within the SPP is the incremental production of components with defined hardening by property-controlled flow-forming. For this purpose, the basic relationships for the development of a multi-sensor system were researched in the first phase, which provides the measurement data for a soft-sensor. With the help of this soft-sensor, the control of the roller feed is taken over during the forming process depending on the hardening measured in the component. In the second project phase, the focus was on the methodology for implementing and further developing property-controlled flow-forming. For the first time, self-regulating flow-forming could be implemented in the digital twin and experimentally on the basis of a process variable. Based on the knowledge already gained and the preliminary work, the experimental implementation of property-controlled flow-forming to produce workpieces with defined strain hardening has been comprehensively prepared. In the proposed third phase, the experimental production of rotationally symmetrical components with a developed hardening design through property control is focus first. In parallel, the production and characterisation of additive semi-finished products from a similar material (in terms of chemical composition) will take place. By characterising the disturbance variables of additive manufacturing and extending the sensor system, the property-controlled flow forming is extended to the forming of additive semi-finished products in order to produce components with defined hardening.

• DFG Programme: Priority Programmes
• Subproject of: SPP 2183: Property-controlled metal forming processes