~ Fraunhofer

IWU

th
5 International Conference
on Accuracy in
Forming Technology

ICAFT 2015
International Conference on
Accuracy in Forming Technology

22 nd Saxon Conference on
Forming Technology SFU 2015
22. Sächsische Fachtagung
Umformtechnik SFU 2015

Proceedi ngs /Tagu ngsband

Editors I Herausgeber:
Prof. Dr.-Ing . Dirk Lan dgrebe
Prof. Dr.-Ing . Welf-Guntram Drossel
Prof. Dr.-Ing . Matthias Putz
Verlag
Wissenschaftliche
L.-_---.;S
;..;;;
cr...iR..;.;
te;.;..;.l
n Reports fram the IWU Volume 88
 !!ß.::;;:;
~ Fraunhofer
IWU

Introduction

The German industry is moving towards new ways of production :

driven by increasing individualization of products and by the
possibilities created by digital networking, the challenge arises to
generate efficient and flexib le process chains that can be adapted
dynamically. This challenge requires more than ever not to
investigate individual technolog ies and process steps separately
from one another, but to consider the comp lete value added
chain as an entity.

Under the topic "Efficiency in Forming Technology by Integrated

Approach to Process (hains" authors from science and industry
present their latest developments and approaches, contributing
to achieve competitive va lue-added chains in the field of forming
technology.

Zum Buch

Deutschlands Industrie ist auf dem Weg zu neuen Produktions-

formen: Getrieben durch die zunehmende Individualisierung der
Produkte und die Möglichkeiten der digitalen Vernetzung steht
die Herausforderung, effiziente, flexible und dynamisch anpass-
ba re Prozessketten zu schaffen. Dies erfordert es umso mehr,
einzelne Technologien und Prozesssch ri tte nicht losge löst zu
untersuchen , sondern die Wertschöpfungskette in ihrer
Gesamtheit zu betrachten.

Unter dem Thema »Effizienz in der Umformtechnik durch

ganzheitliche Prozesskettenbetrachtung « stellen Autoren
aus Wissenschaft und Industrie ihre neuesten Entwicklungen
und Lösungsansätze vor, die zur Erzielung wettbewerbsfähiger
umformtechnischer Wertschöpfungsketten beitragen .

JJb::
UND PRODUKTIONSPROZESSE
Imprint Table of Contents
5t h International Conference
on Accuracy in
Plenary Papers: Effieieney in Forming Teehnology
Forming Technology

22 nd Saxon Conference on Drivers and Challenges on the Path Towards "Industry 4.0" ..... .... .... .. .. ....... ..... 11
Forming Technology SFU 2015 Neugebauer, R.
22. Sächsische Fa ch tagung
Umformtechnik SFU 2015 The Audi Tool shop - Taking the Next Step into th e Digital Dimension .... .... .... 15
Sp indler, J.; Breme, M.; Hein, c.; Struck, R.

Editors:
Sustainability at Hirschvogel ... .. .......... .. .......... .. ... .. .. ..... ..... .... ..... .......... .. ...... .. ..... 33
Prof. Dr.-Ing . Dirk Landgrebe
Raedt, H.-W.; Maurer, O.
Prof. Dr.-Ing . Welf-Guntram Dross el
Prof. Dr.-Ing . Matthias Putz
Lightweighting in Automotive Industry Using Sheet Metal Fo rming -
Advances and Challenges ............ ... ... .. .... .. ..... ... .. .. .............. .. .... ... ......... ... .... ....... . 43
Fa llah iarezoodar, A.; DrotleH, K.; Liewa ld, M.; Altan , T.

Al l ri ghts reserved.
No part of thi s publ ica ti on may be reproduced or transm itted by any means,
electron ic, mechan ical, photocopying or otherwise
without the prior pe rmiss ion of the pub lisher.
Towards Efficient. Interconnected and Fl exible Value Chain s -
Examples and Innovations from Research on Production Te chn o logies ........... 61
Landgrebe, D.; Putz, M.; Schieck, F.; Sterzing, A., Rennau, A.

Sh eet Metal Fo rm ing

The Renaissance of Hydroforming - Solutions for Cu r rent Chall enges in

© 2015
Fraunhofer Institute for Machine Tools and Forming Technology IWU
www .iwu .fraunhofer.de
Verlag Wissenschaftliche Scripten
www.verlag-wi ss-scripten .de
Lightweight Construction, Exhaust Systems and Chassis, Suitable not o nly
for Vehicle Construction .... .. .................. .. ........ .. ......... .. ... ............ .. ......... ... .. ... .. .... 8 1
Freytag, P.
Highly Flexible Forming Technologies - Approach for Rising Di versity
of Variants ...................................................... ... ....... .. ...... ..... ... .. ...... ... ....... .. ......... 91
Weise, D.; Landgrebe, D.

Integration of Press Hardening with Cold Trimming .... ... .. ......... .. .................. 105
ISBN : 978-3-957 35-029-9
Yil maz, 1. 0 .; Kaftanoglu, B.; Hacalog lu, T.; Kilickan, M .
Tooling Flexibility = Flexibility in Forming Technology?!. .. ...... .. ...... .... ... ......... 119 Resource Efficiency in Bulk Metal Forming -
Landgrebe, D.; Krä use l, V; Birnbaum, P.; Quellmalz, J.; Sc hleg el, H.; Selected Strategies ..... ... ........... .. ...... ........... ....... .. .. ... ... ..... ... .. ........ ......... .. ....... .. 269
AI-Obaidi, A.; Guk, A. Muckelbauer, M.; Takale, S; Meyer, M .

A New Approach for the Visioplastic Stress Analysis for Material Development of Hybrid Material Composites for Marine Diesel Engine
Characterisation .. .. ..... .... ..... ......... ...... ....... .. ... ..... ... ...... .. ... .. ... ....... ....... .. ... ........ .. 139 Components with High Thermal Loads .. ...... ... .... ... .. ... ..... ... ... ....... ..... ............. .. 281
Jentsc h, E.; Krüger, L.; Landgrebe, D.; Wag ner, A; Lehnert, T.;
Küsters, N.; Brosius, A.; Schomäcker, M .
Selbmann, R.; Kolbe, P
Precision Cutting: Opportunities and Cost Advantages ...... ........ ....... .. ... ... .... .. 155
Rolling - A Versatile Process of Massive Forming ..... ....... ... ..... .. ..... ....... ... ....... . 289
Stahl, K.
Erxleben, St.
Conductive Heating Opens up Various New Opportunities in
GBQ Micro Finishing of Forged Engine Components ..... ... ........ ........... .. .. ..... .. . 305
Hot Stamping ... .... .. ...... .. ...... ..... ..... ... .... ...... ... ... ..... ........ ... ..... ... ...... .. ...... ............ 157
Witt, Th .
Behrens, B.-A.; Hübner, S.; Schrödter, J. ; Uhe, J.
Robustness Analysis of Metal Forming Simulation - State of the Art
Forming of New Generation AHSS Using Servo Presses ..... .... ...... ... .......... .... .. . 175
in Practice ..... .......... .. .... ......... ...... .... ... ...... ............... ... ... ... ... .... ... ..... .. ....... .... .. ..... 319
Billur, E. ; (etin, B.; Yllmaz, M.M.; Og uz, AG.; Atay, A; Ersoy, K.; Uguz, RO,
Wolff, S.
Kaftanoglu, B.
Innovative Manufacturing Route for Realizing Alternative Drive Concepts ... 335
Manufacturing of Innovative Aluminum Components by Combining
Landgrebe, D.; Sterzing, A.; Schuster, R., Popp, M .
Shear Cutting Operation and Tailor Heat Treated Blank Technique ..... .... ...... 193
Degner, J.; Suttner, S.; Tsoupis, 1.; Lechner, M .; Merklein, M .

Flexible Manufacturing Concepts for a Resource-Efficient Use of Tools

and Production Equipment ... ...... ............. ........ ....... ............... ... ......................... 209 Joining
Fischer, T.
The Door Sidecrash Beam in the New BMW i8: Application of a
Efficient Production of Press-Hardened Components Due to
Press Hardened 7xxx Aluminium Alloy Panel ..... ..... .............. .... .......... ... .. .. ... ... . 349
Optimization of Geometry and Integrated Process Monitoring ....... ...... ...... .. . 229
Rein stettel, M .
Skrikerud , M .; Koroschetz, Ch .; Porzner, H., Lorenz, D.
Virtual Joining Factory - Integration of Microstructure Evolution in
the Manufacturing Process Chain Simulation ..... ......... .. ......... ...... ... ..... ............ 357
Beyer, U.
Bulk Metal Forming
Investigation of the Flange Length Behaviour in Hemming Processes
Potentials of Aluminum-Alloyed UHC-Steel for Components through Numerical Simulation ...... .. .. .. ...... ... .......... .... ........ ... ... ..... ...... .. ............ 367
Manufactured by Bulk Metal Forming .. .............. ... ..... .... ....... ..... ..... ...... ..... ..... . 233 Raja, U.; Kaiser, eh.; Govindarajan, R.; Kulkarni, V.
Beh rens, B.-A; Bouguecha,A.; Vucetic, M .; Kazha i, M .; Yarcu, D.
Process Chain Simulation at Audi Tool Shop .. ........... ... ...... ... ..... ... ..... ........ .. .... . 377
Innovation, Research and Technology Development from the Point of Poelmeyer, J. ; Breme, M .; Wa hl, M .
View of Engine Manufacturer Rolls-Royce .............. ... ............ ............ ......... ...... 253
Tamminen i, S. V; Landgrebe, D., Ste rzin g, A.; Porstmann , S.; Popp, M .
778 5th In ternational Conference on Accura cy in Forming Technology Sheet M eta! Forming 779

Tooling Flexibility Flexibility in Forming

Technology?!
Landgrebe, o. (a, b); Kräusel, v. (a); Birnbaum, P. (a); Quellmalz, J. (a) ;
Schlegel, H. (a) ; AI-Obaidi, A. (a); Guk, A. (a)
a) Institute for Machine Tools and Production Processes, Technische
Universität Chemnitz, Germany
b) Fraunhofer Institute for Machine Tools and Forming Technology IWU,
Chemnitz, Germany

Keywords:
Flexible Manufacturing Systems (FMS) , Incremental Sheet Forming, Heat
Treatment

Abstract
Distinctive customer requests for individualized products , their quick availability and
market accepted price policy influence increasingly production engineering ,
particularly forming technology . Relevant questions focus progressivelyon cost-
efficient production of minimized batch sizes , quick changing product shapes and
individual adjustment of mechanical properties . Rising demands on flexible tool
solutions accompany the call for energy and resource efficient solution strategy to
satisfy customer requirements . Within the IWP (Institute for Machine Tools and
Production Processes) at Technische Universität Chemnitz different tool concepts
were designed , developed and subsequently evaluated . The general request for
innovative tool concepts and technologies to design adjusted mechanical properties
is in focus . By questioning the fundamental construction of forming and cutting
tools, innovative concepts are implemented, whereby shaft guidance and peripheral
units will be neglected. Especially multi-axle driven tools with online position control
are mainly considered. By implementation of innovative control and feedback
control technology highly dynamic forming processes can be realized . Significant
advantages arise from servo-electric actuator units whereby flexible velocity profiles
are implemented . Potential tilting effects are avoided by separate adjustment
control for each actuator.
720 5th In terna tional Conference on Accuracy in Forming Technology
Further aimed flexibility in production technology is implemented for advanced
sheet meta I forming by tools with high degree of freedom and thermally supported
process control. Incremental sheet metal forming therefor represents an ideal
technology . Especially for prototyping and small batch sizes the considered method
is advantageous. The implementation of fast-heating units guarantees a pinpoint
heat input at the forming zone whereby the resource-saving input of thermal energy
is taken into account. The feasibility of enhanced flexibility in terms of local heating
is further examined and evaluated for the process of roll forming with individually
adjusted mechanical properties. Subsequently a customized process window can
be determined and process influences as weil as limits are described . A prospective
view on flexible forming technologies under consideration of energy- and resource
efficiency will be given .
1 rooling flexibility by electric servo drives
The business segment of SME in production engineering tends increasingly to new
demands of fast changing products in decreasing quantity. Furthermore there are
aggravating circumstances like shortened production times at high and rising quality
requirements . Profound innovations in production technology are necessary to
remain globally successful in competition. A promising approach to satisfy market
conditions is an increasing progress of adaptability and flexibility in production
engineering, especially in regard to machinery and tool design. Despite individual
and fast changing customer requests , a maintaining profitability for SME can
therefore be guaranteed.
An increasing request for products of various design , properties and lot sizes
represent ·a major challenge for machine tools and machinery, which have to obey
ever-changing requirement profiles . Traditional construction principles for tools, that
are defined by high quantities, robust processes and uniform manufacturing steps,
need to be questioned. However following general aspects are taken into
consideration , to ensure variability and flexibility:
1. Tools consist of modular-based structure with changeable segments.
2. The field of application is multifunctional. Various production steps can be
realized with the help of one single tool system and several tool modules.
3. Motion and velocity profiles are variable and individually adjustable in different
working directions without loss of fo rce or momentum.
Sheet Metal Forming 727
4. The amount of peripheral components is far reduced, so that the performance
is still ensured but quick module changes are possible .
As a consequence of less supporting structures, a high number of degrees of
freedom as weil as a maximum of flexibility in structure, mechanical components
have to be replaced by alternative systems . Therefore, control concepts and
automation technology need to be taken into account to monitor, adjust and
possibly self-optimize the process in prior defined circumstances . Within the scope
of that concept, various kinds of sensors and actuators are considered for the
innovative tool design. In regard to a higher degree of flexibility, self-driven tools are
focused for future developments whereby cost-intensive machinery can be
neglected . The machine drives for innovative tools are adjusted according to the
required technological processes respectively .
1.1 Concept implementation
Within new developments for innovative press tools, several innovation spots are
defined, which form together the new tool concept.
Flexible construction
Under a constructive point of view a maximum in flexibility is reached by a modular
design , at which several function modules are placed within a basis tool.
Furthermore structural dimensioning is adjusted to a minimum of guidance and
stabilizing parts . Position control within the tool is managed by several single
actuators.
Decentralized drive concept
The implementation of the actuation unit within the tool is part of the innovative
concept, whereas versatile adjustment possibilities for the loading direction can be
achieved. The degrees of freedom for loads can subsequently be better exploited if
there are several drives implemented besides the resulting force axis , instead of a
center-placed single drive above the tool. While independent and variable motion
profiles for the actuators are possible , they need to res pond rapidly to position and
load sensor signals by appropriate feedback control. The optimal drive technology
for individual and flexible motion at consistent force and momentum are servo-
electric drives . Integrated actuators comprised of servo motor and mechan ical drive
train are favored .
722 5th International Conference on Accura cy in Forming Technology
Control algorithms
Beside constructive adjustments, preconditions in measurement and control
technology need to be considered to avoid unintentional tilt at guiding elements.
The position at the guiding elements can be recorded by linear encoders, which are
used to verify the relative position of several drives to each other. Next to linear
measurement, the process can be monitored simultaneously by force measurement
along force-transmitting tool parts . The force signals can be considered to improve
control performance, e.g. by disturbance feed forward strategy [2] . The feedback
control system is responsible to monitor the tool position and to avoid unwanted tilt
by individual adjustment of several drive positions as weil as their speed and
torque .
1.2 Demonstration tool
Theoretical approaches are verified by an innovative self-driven press tool with a
maximum in flexibility as weil as process stability. The demonstrator should
applicate recent productions steps of sheet metal forming such as deep drawing,
bending , punching and further more . Due to the fact that sheet metal forming is
performed by standard hydraulic presses or crank presses, the basis construction of
the demonstrator is similar. A general description of the demonstrator with its set-up
of basis tool , single modules, actuators and control technology is given in Figure 1.
demonstrator
modules
linear actuators
Figure 1: Oemonstrator set-up and according modules
Sheet Me ta! Forming 723
The basis tool (Figure 1, grey) consists of modular die-set that is connected to
linear actuators on opposite sides (Figure 1, green) . Both servo-electric drives are
driven by individual drive units and offer a maximum in power and momentum at
every position , which is required 10 avoid tilt. Since tilt is not avoided by the guiding
elements of their own , maximum forming force depends on the load eccentricity. A
further aspect that recommends the application of integrated servo-electric
actuators is the availability of signals which can optionally be used for feedback
control and/or monitoring at each actuator:
• motor position and speed (rotary encoders)
• actuator active current (torque-proportional)
The calculation of the load forces out of the active current can conditionally replace
explicit force measurement. However, it is implemented connected to a cabinet-
integrated 2-channel charge amplifier. Parallel to the actuator-basis tool-connection
Iwo linear measuring systems (Figure 1, green) are utilized to monitor the relative
movement of the upper and lower plate of the basis tool to avoid unwanted tilt in the
guidance columns . Due to the fact that just two actuators are implemented , the tilt is
just considered one-dimensionally. A two dimensional lilt can just be avoided by at
least three actuators.
Next to the linear measurement system , force measurement by force-linking piezo-
based load washers are integrated along the flow of forces in the single
demonstrator modules as weil as in the axes of the linear actuators . The production
process can thereby be observed as a result of changing forces . At best self-
optimizing algorithms are integrated based on the signals of the load cells .
The demonstrator functions need to be tested and evaluated with the help of
several single load modules that are placed eccentrically in the basis module . Thus
an unbalanced load can cause tilt in the guidance which needs to be compensated
by the feedback control system . The single load modules can be placed
eccentrically as weil as centrally in the basis module. In Figure 2 the assembly of
three load modules is illustrated .
724 5th Interna tional Conferen ce on Accuracy in Forming Technology Sheet Metal Forming 725

h~licEl spring processes are illustrated and calculated exemplary with the help of the FE software
module elastqmer spring
cutting. LS Dyna to gain results for maximum forces and the corresponding displacement.
modul!,! mod 1,1 le
The considered values of forces and displacement depend strongly on the material
that is formed or cut. The force vs. stroke curve is significantly influenced by the
examined production process and the considered material (Table 1).

Table 1: Numerieal ealeulated foree-displaeement-behavior for individual manufaeturing proeesses

Figure 2: Load modules with integrated load eells (gre en) and fun e/ion uni! (yellow)
ben ding u-bending cutting deep drawing

penetration
These three single load modules are different in their construction and accordingly depth at 10 0.3 appr. 11
different in their force-displacement-behavior. The spring modules serve as Fmax- [mm]

comparable module to real processes deep drawing or bending . Therefor the force- F ma,. [kN]
5.8 43 9.4 25
DC04
displacement-characteristics are prior FE-calculated and basis for dummy load
modules that replace real deep drawing or bending tools. Due to the integration of Fmax. [kN] 11 36 7.3 35
AIMg3
load cells (green marked in Figure 2), acting forces in the module can be detected
and compared with forces in the actuator axes . The influence of an eccentric load Fm.". [kN]
48 144 20 > 52
Ck45
ca se on the basis module can be evaluated .

Corresponding to the results gained by FE-simulation , alternative dummy modules

1.3 Flexibility by dummy modules are designed and adapted . In Table 2 the calculated values for the considered
dummy modules are listed to illustrate Ihe comparability to the FE-calculated
As a result of developments for cost-efficient tool design , alternative systems in production processes .
form of abstract test modules - so-ca lied dummy modules - replace real tools for
The resulting force vs. stroke curves for dummy modules are comparable with real
forming and punching . The force vs . strake curve of dummy modules is so far
productions steps , which are required to obtain reliable results for further
adaptable that several real processes can by replaced perfectly. Major advantages
investigations. The application of alternative modules can therefore be taken into
of dummy modules are an exact reproducibility , no need in further material and the
account. Especially under consideration of tool characteristics al eccentric loads,
force vs. stroke curve can be adjusted individually for many kids of tools . An
reliable and reproducible results are gained experimentally. For an individual
idealized comparison between theoretical aspects of production processes and
dimensioning for lools with eccentric, high dynamic and adjustable loads the
dummy can be fulfilled with the help of FE simulation. The simulation results are
procedure of theoretical analysis, simulalion and exemplary implementation of
basis for design and dimensioning of dummy modules. In Table 1 four production
alternative dummy modules offers promising results .
726 5th International Conference on Accuracy in Forming Technology Sheet Meta! Forming 727

Table 2: Experim entally determined force-displacement-behavior of considered dummy modules

electrical drive mechanics

elastomer spring
dummy coi/ spring module cutting module
module electromechanical axis

displacement Figure 3: Classical axis control architecture [3J

29 19
[mm]

7.3 (AIMg3) To increase the fle xibility, the positioning co ntrol and set point generation could be
Fmax[kN] 97 28 9.4 (OC 04) integrated in the drive units as weil (in the following ca lied "d rive based
20 (C 45) architecture") , since modern drive units have high computation performance and
ofter lots of advanced options for positioning and operation without superordinated
motion controller (i .e. use standard PLC). The following Table 3 lists pro (+) and
contra (-) of the architectures.
1.4 Control system
Table 3: Evaluation of considered criterions for differen t contral / contral feedba ck architectures
The control/feedback control system has to consider the fle xibility of the mechanical
criterions classical architecture drive-based architecture
and actuation system. Every linear actuation unit needs its own drive power unit of
course . Classically, these comprise the cascaded current and speed control loops positioning controllag and
++
sampie times
while position control and set point generation is situated on a superordinated
controller (besides sequence control and general 1/0) , as shown in the following implementation 0'
direct
position control (linear ++ -
Figure 3 (in the following called "classical architecture"). measurement system)

synchronization afford /
++ -
'ai/ure detection

adaptability (add/remove
+
actuators)

costs - +

Although a classical architecture has some more benefits for the laboratory state in
implementation of testing software, supervisory measurement etc. , for the
implementation at the shop-floor a drive-based solution is favored . If sufficiency of
the feedback control performance with th e classical architecture can be proven at
728 5th International Conference on Accuracy in Forming Techno!ogy Sheet Meta! Forming 729

the laboratory state, a drive-based solution will work weil also, since its performance
is expected to be better. If further improvement is required , specialized control for
mechanically coupled multi-drive systems [1] can be taken into account. These
include coupling between the actuators besides set point only.

2 Flexibility by using universal forming tools

2.1 Hot single-point incremental forming

2.1.1 Demand in flexible forming concepts

Complex sheet metal shapes can be formed cost-efficiently by an innovative

forming method called single point incremental forming SPIF . In contrast to Figure 4: Experimental set-up for fle xible and localized hot single-point incremental forming
conventional forming processes like bending or deep drawing, that requires
expensive fixtures and tools . SPIF is suitable for prototyping and customized 2.1.3 Experimental investigations on SPIF
productions . Complicated shapes are gained with the help of simple tool assembly .
Even high strength steel AHSS can be formed to complex shapes by SPIF with the Due to flexible heat treatment the formability of MBW1500 alloy sheet is increased .
help of thermal activated processes (e.g. Duflou et al. [4], Ambrogio et. AI. [5], Fan As illustrated in Figure there are two formed parts. One was fully hot formed with
et al. [6] and further [7]) . 70 ° wall angle by induction heating (see Figure 5 (a)) , whereas the part formed at
room temperature failed although the wall angle was only 66 ° (see Figure 5 (b)) . As
The motivation of the current research investigation is to find a new and flexible
stated by Van et al. , [8] the employment of flexible heat influence is the first reason
heating strategy that can heat the blank sheet to a temperature more than 650 °C for
for the improvement of formability for the hard to form high strength metals.
flexible forming of AHSS. Thermally activated forming processes offers decreased
forming forces which is achieved by forming with SPIF and synchronized induction Further aspects are reduced forming forces by additional he at. A cylindrical profile
heating. was formed from MBW1500 alloy sheet once with induction heating and another
time without heating by fixing the forming parameters. As illustrated in Figure 6 the
forming forces were measured by Kistler multicomponent dynamometer that is
2.1.2 Materials and principles of the investigated set-up
placed between the holding fixture and the CNC machine table . The results are in
Figure 4 exhibits the investigated set-up that was applied in the experiment. Three full agreement with Duflou et al. [4]. The forming forces are reduced significantly at
tools made of KXF tungsten carbide with diameters of 8, 10 and 12 mm were used. hot forming .
The induction heating was supplied by an induction machine of 50 kW as a
maximum capacity and a fixed frequency of 350 kHz. The sheet blank placed on a
guided fixture was considered to allow a higher flexibility in movement of the
inductor. The heating temperature was measured by infra red camera from -40 to
1700°C. The formed profiles are of pyramidal and conical shapes made from a
spiral tool path of a fixed incremental depth = 0.5 mm . Furthermore , the feed rate
and induction power were flexible va ried to control the generated heating
temperature.
130 5th International Conference on Accuracy in Forming Technology Sheet Meta! Forming 737

6000
• elevated temperature
Z 4000
Q)

...o • room temperature

~ 2000

o
X-axis
Y-axis
Figure 6: Forming forces: comparison between hot forming and cold forming of parts made of
MBW1500 steel sheet

Figure 5: Conical formed profile (a) hot formed, (b) formed at room temperature
Since the induction heating was affecting the hardness of the DP1000 steel the
micro hardness was measured at the formed part produced with assistance of
There are affecting parameters to influence individually the forming temperature .
induction heating. A reduction of hardness was found at the formed sheet metal part
The most influencing parameters on the sheet temperature during induction heating
due to the excessive induction heating as shown in Figure 8.
are the feed rate and induction power. Fan et al. [9] also found a high relation
between current power and feed rate on the temperature generated in the sheet.
From Figure 7 it can be noticed that the sheet temperature increases by decreasing 950
feed rate especially when forming with a high induction power and vice versa.
u
o

Furthermore , there was an inhomogeneous distribution of heating temperature ~ 900

::J
.-
between the pyramid and conical profiles. It was found for the formed parts form the co
.....
DP 1000 alloy steel of 1.6 mm in thickness that inhomogeneous distribution of Q) 850
Q..

temperature during forming between the depth levels in the produced profile. This E
problem was solved by AI-Obaidi et al. [10] . However, when forming there was a ~ 800 . 1250 mm/rnin
.-
Q)
difference in heating temperature between the pyramid and the conical formed Q) .1 000 rnrn/rnin
profiles. Fan et al. [6] discovered the heat distribution in the conical profile was J::
Cf)
750
. 750 mrn/rnin
much better than in the pyramid profiles . In the same time , the temperature "C
Q)
distribution in the pyramid formed part was inhomogeneous especially at the E 700
.....
corners. The former mentioned problem was solved by applying a higher feed rate o
u.. 650
when forming at the pyramid corners .
45 kW 40 kW 35 kW
Induction power
Figure 7: Sheet temperature affected by feed rate and induction power for sampies formed from DP
1000 steel al/oy
732 5th International Conference on Accuracy in Forming Technology Sheet Meta! Forming 733

In fact, this can be considered as a disadvantage of induction heating. Especially at beneficial to produce steel sheet profiles with tailored properties zones in a
the profile corners the Vickers hardness was measured with a value of 170 HV1 in continuous process . In that case , roll forming is a very effective and low-cost
comparison to 260 HV1 for the unheated sheet metal. The mentioned problem was manufacturing process of straight , opened and closed profiles. A flexible and locally
solved by AI-Obaidi et al. [10] . The induction heating was controlled by making a limited heat treatment with subsequent cooling section offers the possibility to
relation between the resulting profile depth and the forming parameters . produce roll formed components with tailored properties in longitudinal as weil as in
Following conclusions can be drawn for flexible single point incremental forming transverse direction. Additional advantages of this technology are:
with thermal support. DP 1000 and MBW1500 alloy steel sheet were heated by • the reduction or substitution of handling operations (according to TTA- and
induction heating and simultaneously formed by SPIF . The most effecting CCT-diagrams , long holding times are not required for specific time
parameters on the temperature produced in the sheet are the induction power and temperature strategies)
feed rate . A new flexible forming technique was performed , depending on the direct • the minimizing of spring back (according to press hardening)
relation between the comp lex sam pie geometry and the temperature difference.
• the production of components with tailored properties without support of
comple x tool technology
300 -'--
• short cycle times
250 I • the implementation of high application amounts
....
>
.,
:I: 200
I1- - Th e process flow can be compared with the indirect press hardening . First the sheet
=>
~ 150
I, is pre-formed and then according to the final component requirements , it is locally
I, heated up to austenitization temperature and immediately quenched at the exit of
.,:::l the rolling tool (Figure 9).
c:::
!
..
"E 100
:I: 1
50 L
0 r - ---- __• - - -0- ____
---,
0 20 40 60 80
Distance from the proflle center mm cooling
device
Figure 8: Cross seetion of a fully formed profile (right) and comparison between the hardness value
and an enlarged half profile form (Ieft)

2.2 Profile rolling with flexible heat treatment

Figure 9: Roll forming unit with integrated heating device (schematically)
2.2.1 Integration of induction heating in the roll forming process

The increase in productivity while reducing production times has been a continuing The most significant advantage is the production of hardened parts in a continuous
trend. Therefore , new heating technologies have been integrated more and more process , which is connected to an increased flexibility in machinery and a shortened
into forming processes , resulting in a more compact design of the production set- process chain [1 3]. However the mentioned flexibility does not always correlate with
up. The combination of roll forming with an integrated local heat treatment is
134 5th In terna tional Conference on Accuracy in Forming Technology Sheet M etal Forming 135

considered process windows due to the discrete of flexible heat treatment , rates (Figure 10). Further a progressive homogenization occurs between theoretical
especially heating velocity. Ac3 and forming temperature .

Prior research investigations (12) , (14) described changing mechanical properties at

single step fast inductive heat treatment of 22MnB5 steel alloy. Accordingly - . - 1 fVs 1000 ' C
-0- ; 5 Kl s
induction heating with 20 seconds soaking time is comparable with conventional - 0 - ' 10 K's
-0- , SJ Kls ..._____ -
furnace heating. Further investigations to compare the influence of heating rate with
mechanical properties are given by Korpala et.al. (11) . Differences in flow behavior CI - - - - - - - - - 0
- " 0
o ~o~
after conventional , conductive and inductive heat treatment were found. Increasing ~ o
2 ~--~~-----------=----~
heating rates tend to higher initial yield strength in the material, wh ich is described 70,----------;:-;
1
950
" ""'
C- - - - - - - - - - . . ,
by an inhomogeneous microstructure , grain growth and state of precipitation . <ij' 6
.------
0..
~ 50
!l~Q ",,--O
2.2.2 Experiments for flexible inductive heat treatment ~l j 0 ........-------0 __--Id
0 _ _ _0

The investigations to the influence of heating rate on the mechanical properties are
2~----------------------~
executed for 22MnB5 steel alloy with 2 mm sheet thickness . The mechanical =-:-'c= --- ---------,
' 00'-- ---------::-900
9
properties of the material at different heating rates were described by the <ij' 80
determined flow curves . The aim was to analyze how far different heating rates 0.. 7
::;:
-
influence the flow behavior. Testing temperatures varied between 900 e, 950 e
o 0
.. 6
~!:.
and 1000 e as weil as the deformation velocity between 0.01 s·" 0.03 S·1 and
0

0.05 S·1. These parameters correlate with appearing values of the roll forming 00' o,
Strai n rate [s" ]
processes with integrated heat treatment. The heating rates are defined according
to preliminary investigations [13] as described in Table 4. Figure 10: Relation between k 'max and strain rate

Table 4: Examined heat rates according to the roll forming process

forming
heating rate [K/s]
temperature 1
Conclusions
strain rate [5. ]
to 750°C from 750°C ["C]
The transition to greater flexibility of forming tools and processes are current topics
75 10 900 0.01 in production of sheet metal parts .
11 0 15 950 0.03
By utilizing decentralized actuation instead of traditional press setup , flexibility is
150 30 1000 0. 05
increased by reducing effort of retooling and also space requirement. On the
downside , maximum forming force is not simply the sum of the forces of the single
The phase transformation was considered next to the flow curve investigations. The actuators, since process-dependent eccentric load has to be taken into account.
results from the tension tests (especially kfmax ) offer a relation to all considered Also , at this time , cost of high-integrated servo-electric actuators is still quite high
parameters. By increasing temperature the microstructure homogenize more and maximum forces are limited . So, it is obvious to use this concept for small batch
regularly with results in lowered yield strength. Furthermore it was found that flow production of smaller pieces.
stress is decreasing with increasing test temperature and additionally at high strain
736 5th International Conference on Accuracy in Form ing Technology
The synchronizing of induction heating and incremental forming operation together
to be performed at the same time offers not only the chance to reduce the
production time , but also to form high strength sheet metals into complex profiles.
Moreover, due to the reduction in the forming forces and controlling the sheet
temperature during forming the suggested process presents a flexible method to be
applied in wide applications.
The direct heat treatment during roll forming of profiles exhibits a feasible operation
for reduction process time: Instead of three single process steps the manufacturing
of profiles with tailored properties can be realized in one continuous operation step.
In the same time , the difficulty in controlling the steel phase transformation was
homogenized by controlling of the investigated parameters like cooling rate ,
induction power and rolling speed. The identified nonhomogeneous distribution of
heating temperature needs more improvements by simulating and experimenting for
a deeper understanding of influencing effects .
It can be stated that the opportunities for flexibilization are manifold, but associated
with some limitations in part geometries and uniform properties or in application of
forming forces required . Therefore the tooling flex ibility stands only partially for
flexibility in forming technology.
References
{1} Rehm, M; Schlegel, H.; Drossel, w.-G .; Control strategies for mechanical/y-
coupled high speed linear drives; The 9th International Symposium on Linear
Drives for Industry Applications LDIA '2013; Hangzhou, China ;Springer Berlin,
2013. - Lecture Notes in Electrical Engineering, p. 273
{2} Komada, S.; Ishida , M ; Ohnishi, K. ; Hori, T.; Disturbance observer-based
motion control of direct drive motors; Energy Conversion , IEEE Transactions
on, vol.6 (1991), p.553-559
{3} Schönherr, R; Regelkreisüberwachung mechatronischer Antriebssysteme.
Dissertation; Verlag Wissenschaftliche Scripten, Auerbach/Germany; ISBN:
978-3-942267-56-4, 2012
{4} Duflou,J R; Cal/ebaut, B.;Verbert, J ; Oe Baerdemaeker, H; , Improved SPIF
performance through dynamic local heating; International Journal of Machine
Too/s and Manufacture; 48 (2008) ; p. 543-549
Sheet M eta l Forming 737
{5} Ambrogio, G.; Filice, L. ; Manco, G. L. ; Warm incremental forming of
magnesium al/oy AZ3; CIRP Anna/s - Manufacturing Technology 57 (2008) p.
257-260
{6} Fan, G.; Gao, L.; Hussain, G.; Wu, Z.: Electric hot incremental forming: A
novel technique; International Journal of Machine Too/s and Manufacture 48
(2008) ; p. 1688-1692
[7} Adams, D. W. et. al.; Improvements on Single Point Incremental Forming
through Electrical/y Assisted Forming; Contact Area Prediction and Tool
Development, Queen's University Kingston , Ontario, Canada.
{8} Van Sy, L.; Thanh Nam, N. ; Hot incremental forming of magnesium and
aluminum al/oy sheets by using direct heating system; Proceedings of the
Institution of Mechanical Engineers, Part B: Journal of Engineering
Manufacture 227 (2013); p. 1099-1110
{9} Fan, G.; Gao, L.; Mechanical property of Ti-6AI-4V sheet in one-sided electric
hot incremental forming~· The International Journal of Advanced Manufacturing
Technology (2014)
{10} AI-Obaidi, A; Kräusel, V.; Landgrebe, 0.; Improvement of formability in single
point incremental forming of DP1000 steel aided by induction heating; WGP
Congress (2015)
{11} Korpala , G.; Kawal/a, R. ; Identifikation erwärmungsabhängiger Einflüsse auf
die Fließeigenschaften von Stahl und Aluminium; Schmiede Journal (2013); p.
36-38
{12} Kol/eck, R. ; Veit., R. ; Merklein , M ; Lechier, J ; Geiger, M ; Investigation on
heating for hot Stamping of boron al/oyed stee/s; CIRP Anna/s -
Manufacturing and Technology (2009); p. 275-278
{13} Kunke , A ; Guk, A; Kräusel, V.; Microstructure evolution during rol/ forming
with integrated heat treatment; AutoMetForm/SFU (2014); p. 155-164
{14} Tröster, Th.; Niewel, J ; Einsatz des induktiven Erwärmens von Platinen und
Ermittlung der entsprechenden Prozessfenster für das Presshärten;
Forschungsvorhaben P 805/IGF-Nr. 16319 N (2014)