Wear model for the prediction of electrode lifetime in resistance heating for hot stamping

• Applicant: Dr.-Ing. Sven Hübner
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 509812086

The process of hot stamping was established in the automotive industry in order to meet the component requirements with regard to crash safety and at the same time lightweight construction. Resistance sheet metal heating is a process that offers the potential for significant energy savings and allows the sheets to be heated up in seconds. However, no data on electrode wear for this process is available in the literature. However, the wear effects in the first phase of heating are similar to those of the electrodes in resistance welding. The present knowledge will be used as a basis. The aim of the project is the basic scientific research and description of electrode wear during resistance heating. An analytical wear model is to establish. With this model, the prediction of the expected electrode life should be possible. The model of ZHANG for the description of the contact resistance during resistance welding serves as a basis for the model development, which is extended by relevant electrode wear parameters of the resistance heating. From this, an analytical wear limit model for the prediction of electrode life will be developed. The parameterization is carried out with experimental tests, for which an electrode wear test rig is being set up within the project. Resistance heating and hot stamping tests are used for the scientific evaluation of the heating results with the used electrodes.

• DFG Programme: Research Grants