SUNConferences, COMA '13

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The Importance of Modern Material Characterisation Methods in Energy Efficient Sheet Metal Forming Process Development
Patricia Nanette Weigel, Roland Müller, Alwyn Bester, Matthias Demmler

Last modified: 2013-08-21


The need to use energy and raw materials more efficiently and the ever increasing customer requirements are forcing automotive producers and the sheet metal forming industry to use lightweight construction materials. Materials such as aluminium, magnesium, ultra high strength steels and tailored blanks are rapidly gaining importance in the forming industries. These modern sheet metals dictate both the layout of the forming tools and the forming processes, often forcing industry to consider innovative production methods like press hardening, hydroforming or high speed forming to ensure that the required component quality is maintained. An essential prerequisite when employing modern sheet metals and innovative forming technologies are reliable flow curve, work hardening, technological boundaries and tribological systems information. A concept that takes a holistic approach to determining forming relevant parameters, considering the requirements of FE-simulation in particular, was developed at the Fraunhofer Institute for Machine Tools and Forming Technology IWU. Within this concept established testing methods are combined with new and innovative characterising concepts used to describe phenomena like spring back, anisotropy and the Bauschinger effect. The interaction between the work piece material, the tool material and the lubricant can, with the help of this information, be described more precisely in an FE-simulation. The implementation of this knowledge in practice, in combination with FE-simulation, contributes significantly to more effective method planning, tool layout and manufacture. The presentation gives a short overview of the research results to date and show the new challenges for material characterisation. A summary of some of the latest material testing developments at Fraunhofer IWU will also be shown.

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