Incremental high speed forming processes

• Applicants: Professor Dr.-Ing. Werner Homberg; Dr.-Ing. Maik Linnemann; Dr.-Ing. Verena Psyk
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2020
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 425908346

The economical production of complex sheet metal components with a high number of variants in small quantities is hardly possible with conventional forming processes such as multi-stage deepdrawing processes, as the tools used in these processes are closely linked to the respective component geometry. Even minor geometry changes require cost-intensive reworking or the production of new tool sets. The overarching aim of the planned project is therefore to develop innovative, flexible manufacturing processes with the associated tool technology for this range of applications. Specifically, the impulse currentbased high-speed forming processes EMU and EHU are to be expanded to include an incremental approach to electromagnetic incremental forming EMIF and electrohydraulic incremental forming (EHIF). As a result, the known process-specific advantages of high-speed forming and the advantages of incremental forming complement each other. The research results of the first funding period have shown that with regard to the main shaping of flat components, EMIF and EHIF can in principle achieve results comparable to those of incremental forming with a spinning graver. However, the expected high potential in terms of shape and dimensional accuracy has not yet been fully demonstrated due to dynamic effects. Building on this knowledge, the research focus in the second funding period will be on the detailed analysis of the influence of the incremental process character on rebound effects and the development of strategies to improve dimensional and shape accuracy by reducing rebound in EHIF/EMIF. The overarching objective of the entire research project, i.e. research into the innovative incremental high-speed forming processes EMIF and EHIF including the associated tool tech-nology for the economical production of high-quality large-area sheet metal components with a large number of variants in small quantities, remains unchanged. However, the complexity of the geometries under consideration will be significantly increased compared to the investigations in the first funding period.

• DFG Programme: Research Grants