Programme

28th ASK Metal Forming

7th and 8th March 2013 Eurogress Aachen

Institut für Bildsame FormgebungProf. Dr.-Ing. Gerhard HirtProf. em. Dr.-Ing. Reiner Kopp

From materials to Products

Steel and Non-Ferrous Metals

1

Venue and Starting Time

All presentations are held in the Europasaal of the Eurogress Aachen. Lunch and a lunch snack are offered at the Eurogress. The champagne reception takes place on Thursday, 7

th March 2013 in the

Karminsaal of the Pullman Aachen Quellenhof and leads to the evening event in the Berlin-Saal of the Quellenhof.

Begin of Presentations: Thursday 07.03.2013 9:00 a.m. Friday 08.03.2013 8:30 a.m.

Important Telephone Numbers and Addresses

Office Building: Institute of Metal Forming Intzestr. 10 52072 Aachen Tel.: +49 241 80-95907 Fax: +49 241 80-92234

Homepage IBF: www.ibf.rwth-aachen.de Homepage ASK: www.ask.ibf.rwth-aachen.de E-mail: ask@ibf.rwth-aachen.de

Postal Address: Institut für Bildsame Formgebung der RWTH Aachen 52056 Aachen

Conference Venue: Eurogress Aachen Monheimsallee 52 52062 Aachen Tel.: +49 241 9131-0

Conference office in the foyer of the Eurogress Tel.: +49 241 9131-555 Fax: +49 241 9131-556

Opening Hours of the Conference Office:

Thursday 07.03.2013 7:30 a.m. – 6:00 p.m. Friday 08.03.2013 7:30 a.m. – 2:30 p.m.

In any cases of urgency during the evening receptions on Thursday and Friday, participants can be reached at telephone number +49 241 9132-0.

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28th ASK Metal Forming

Metal forming processes significantly influence the cost and characteristics of products in many process chains of the metalworking industry. Therefore a sustainable and highly efficient use of energy and natural resources has been pursued in the design of processes and facilities for a long time, not least for economic reasons. Hence improving upon these achievements is even more challenging. This can only be done by optimising the interactions between prod-uct shape, material properties and forming processes in a holistic way. Accordingly, the 28

th ASK Metal

Forming addresses current issues and trends under the motto "From Materials to Products".

A resource-efficient forming process begins with the provision of electric energy for power-intensive forming machines. In addition, innovative designs, a more efficient use of materials, long-lasting products and an extensive recycling leads to sustainable products.

Using modern measuring technology and innovative methods allows the efficient use of resources linked with the improvement of product quality. Particularly in the case of classical forming processes like ring rolling or open die forging, the use of laser measurement technology and a process parallel microstructure calculation for example, result in less material use. In addition, the development of new high-performance materials provides a longer service life and new fields of application.

Lightweight designs for low-emission and energy-saving mobility can be implemented not only by light-weight materials and load adjusted designs such as tailor rolled blanks, but also by the metal forming process and microstructure optimization which will ultimately lead to a better properties/mass ratio. By numerical simulations, the material properties can be calculated before the process. The latest methods will also permit to consider uncertainties in the process control and to make a statement about the robustness of the process. In addition, fast computational models are used to optimize the process within a short time without using FEM so that target values can be evalu-ated fairly precise.

3

Even when individual process steps already contribute to an environmentally friendly product manufacturing, so a holistic systemic approach is required, which provides a particular challenge in the area of multi-material design. By using innovative and novel meth-ods, as well as for the incremental sheet metal form-ing, new lightweight designs are implemented. Self-supporting lightweight constructions show impressive how forming technology and lightweight design can be combined.

The strip casting is a process of particular im-portance for sustainability, since on the one hand the process chain can be shortened and on the other hand, the use of more efficient materials is possible. This allows novel concepts such as the casting of tailored strips. In total, this results in a process chain, which includes all steps from metallurgy to the near-net-shaped product.

The presentations on the above topics will be simulta-neously translated into English. The accompanying exhibition offers the opportunity for contact with lead-ing companies of metal forming. Presentations of the Institute of Ferrous Metallurgy and the Institute of Metal Forming complement the exhibition. In addition, on Friday afternoon, there is a chance to visit the institutes and to see presentations on the topics pre-sented in the program.

Together with our colleagues from the IBF, we would like to welcome you at the 28

th ASK Metal Forming in

Aachen.

Gerhard Hirt Reiner Kopp

4

Innovations within the last 3 years

Portable digital microscope A new measurement microscope Key VHX-600 was added to the equipment of the IBF in 2012. The device was bought in context to the DFG-project “Formgebung großflächiger metal-lischer Oberflächen mit Ribletstrukturen”. It allows high resolution scans of 3D structured surfaces and thereby to measure the topography.

Novel test bench for hot tensile test To analyse the temper-ature depending form-ing properties of sheet samples, the IBF has realized a test bench in which the samples are conductively heated. The application of a thermographic camera enables the measure-ment and control of the

samples’ temperature. This is used to analyse the homogenisation of the temperature and strain field during the hot tensile test at temperatures of up to 950 °C.

Instauration of the Schenck testing machine Since 1976 the Schenck testing machine has been used for multiple, multistep hot and cold bulge experi-ments. In 2012 the instauration of the hydraulics and the control system will be completed. This enhances the measurement of the test data and increases the experimental range, especially in the field of multistep testing with included flexible heat treatment.

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Expansion of the furnace capacity With regard to the project “Sonderforschungsbereich 761 – Stahl ab initio” a new electrically heated batch furnace (N761) of the company Nabertherm GmbH was installed. The internal space can be heated up to 1200 °C and has the following dimensions 800 x 1900 x 500 mm³. Furthermore the gas furnace of the open die forging press was refurbished. The insulation was completely replaced and a programmable control system was integrated.

Expansion of the zmb The “Zentrum Metallische Bauweisen“ (zmb) which was already founded in 1993 merges the research of six institutes of the RWTH and thereby supports the interdisciplinary and holistic development, testing and manufacturing of innovative metallic design tech-nologies within the whole production chain. The exper-imental facility of the zmb, which was built in 2002 was extended by 24 Meters. Until the end of 2012 the department of sheet metal forming and the machine for hybrid incremental sheet forming will move to the zmb.

New machines in the material testing laboratory In 2012 a deformation dilatometer and a torsion plas-

tometer of the company Bähr Termoanalyse will be put into operation, thus considerably increasing the ability of the material testing laboratory to determine

characteristic material values. With high precision torsions plastometry and deformation dilatometry it is possible to gain for example transition diagrams in dependence of arbitrary thermo mechanical material treatments. Additionally the recrystallisation kinetics at considerably higher deformation grades can be ob-tained.

6 Thursday

Programme

Thursday, 7th March 2013

1. Opening Presentations of the 28th ASK

09:00 a.m. G. Hirt*, RWTH Aachen

Welcoming Speech

09:15 a.m.

Presentation

1.1

H. J. Kerkhoff*, Stahlinstitut VDEh und

Wirtschaftsvereinigung Stahl,

Stahl-Zentrum, Düsseldorf

Steel - Basis for Industrial Value

Creation in Germany

- Economic situation of the steel

industry

- Strong industrial value creation

chains as a key factor for the Ger-

man economy

- Challenges posed by energy and

climate policy

09:45 a.m.

Presentation

1.2

H. Ferkel*, O. Hoffmann, L. Keßler,

ThyssenKrupp Steel Europe AG,

Duisburg

Resource-Saving Light Weight

Design for Today’s and Oncoming

Mobility

- Requirements for materials by

automotive applications

- New steel grades

- Sandwich materials

- Hot forming / press hardening

- Sustainability / LCA

*Speaker 7

10:15 a.m.

Presentation

1.3

J. Schönbeck*, SMS Meer GmbH,

Mönchengladbach

Ecoplants – Examples for Re-

source-Efficient Metal Forming

- Sustainable or profitable? It’s AND,

not OR.

- System for the ecological evaluation

of production processes

- Energy and raw material savings by

innovative machines and processes

10:45 a.m. Break, Trade Exhibition and Poster

Exhibition

2. Sustainability Chairman: P. Groche

Technische Universität Darmstadt

11:30 a.m.

Presentation

2.1

R. W. de Doncker*, RWTH Aachen

Future Energy Grids – Conse-

quences for the Metal Industry

- Future electricity supply

- DC technology

- Transmission lines for future elec-

tricity networks

- Requirements for future electrical

sheets

12:00 p.m.

Presentation

2.2

J. M. Allwood*, University of Cam-

bridge

Saving our Metals Energy

- Material efficiency

- Lightweight design

- Long-life products

- Re-use

8 Thursday

12:30 p.m.

Presentation

2.3

M. Feldmann*, RWTH Aachen

Sustainability by Improved Struc-

tural Concepts, Buildings and

Infrastructure

- Steel structures

- Sustainability

- Resource efficiency

- Embodied energy

- Structural flexibility

1:00 p.m. Lunch break, Trade Exhibition and

Poster Exhibition

3. Process and Material Development Chairman: B.-A. Behrens

Leibniz Universität Hannover

2:15 p.m.

Presentation

3.1

D. Rosenstock*, D. Recker, G. Hirt,

RWTH Aachen

R. Rech, A. Tewes, Buderus Edelstahl

GmbH, Wetzlar

B. Gehrmann, ThyssenKrupp VDM

GmbH, Altena

K.-J. Steingießer, D. Sommler, SMS

Meer GmbH, Mönchengladbach

R. Lamm, S. Kirchhoff, MINTEQ

International GmbH FERROTRON

DIVISION, Duisburg

Pass Schedule Optimisation and

Visualization of Open Die Forging

- Fast calculation models for effective

strain, temperature and grain size

- Application for process design and

visualisation of industrial processes

*Speaker 9

2:40 p.m.

Presentation

3.2

J. Klöwer*, N. de Boer, H. Funda, F.-J.

Wahlers, ThyssenKrupp VDM GmbH

Open Die Forging of High Perfor-

mance Alloys: Nickel Alloys for

Power Plants of the Future

- 700°C power plants

- Alloy 617B

- FEM simulation

3:05 p.m.

Presentation

3.3

V. Jenkouk*, J. Seitz, G. Hirt,

RWTH Aachen

Ring Rolling of Rings with Non-

Rectangular Cross-Sections

- Utilization of contoured axial rolls

- Laser measurement of the cross-

sectional profile

- Finite element analysis

3:30 p.m.

Presentation

3.4

W. Bleck*, RWTH Aachen

Design of Damage Tolerance in

High-Strength Steels

- Damage development

- Failure mechanisms

- Microstructure

- Multiphase steels

- Modelling

3:55 p.m. Break, Trade Exhibition and Poster

Exhibition

10 Thursday

4. Material Models and Process Chains Chairman: R. Kawalla

TU Bergakademie Freiberg

4:30 p.m.

Presentation

4.1

B. Buchmayr*, Montanuniversität

Leoben

J. Klarner, voestalpine tubulars

GmbH&CoKG, Kindberg, Österreich

Optimization of Processing Routes

for Tubular Products

- Processing steps and parameters

for thermo-mechanical rolling of

tubes according to the service re-

quirements

- Manufacturing of complex geome-

tries for light weight structures and

production of fine-grained micro-

structures with superior mechanical

properties

- Numerical simulation of relevant

processing steps

4:55 p.m.

Presentation

4.2

T. Henke*, M. Bambach. G. Hirt,

RWTH Aachen

Consideration of Uncertainties in

Microstructure-Based Material

Models for Simulating Hot Forming

Processes

- Determination of material models

- Incorporating experimental and

material based uncertainties

- Through process modelling to

manufacture gearing components

- Target values: microstructure,

process forces, die stresses

- Prediction of target values in proba-

bility distributions

*Speaker 11

5:20 p.m.

Presentation

4.3

J. Hirsch*, K. Karhausen, H. Aretz

Hydro Aluminium Rolled Products

GmbH, Bonn

Simulation of Processing and Prop-

erties of Aluminium Sheet for Au-

tomotive Applications

- Heat-treatable and non-heat-

treatable Al alloys

- Processing, solution annealing,

storage

- Formability, age hardening,

anisotropy

5:45 p.m.

Presentation

4.4

S. Seuren*, M. Bambach, G. Hirt,

RWTH Aachen

Sensitivity Analysis in Modelling of

Plate Rolling

- Fast models for rolling force and

microstructure

- Influence of parameter uncertainty

7:30 p.m. Champagne Reception in the Ka-

minsaal of the Pullman Aachen

Quellenhof

8:00 p.m. Evening Event in the Berlin-Saal of

the Pullman Aachen Quellenhof

- Welcome address by the rector of

RWTH Aachen University

- Bestowal of study award “Metal

Forming“ by the company

Schwermetall Halbzeuge GmbH and

the IBF

12 Friday

Friday, 8th March 2013

5. Strategy and Change Chairwoman: M. Merklein

Universität Erlangen-Nürnberg

08:30 a.m.

Presentation

5.1

G. Hirt*, RWTH Aachen

Change in Research and Education

- Strategy and structures at the RWTH

Aachen University

- Education in the new bachelor/

master system

- Advanced Materials and Processes

research cluster (AMAP)

- Research topics at the IBF

09:00 a.m.

Presentation

5.2

H.-T. Junius*, C.D. Wälzholz GmbH,

Hagen

Innovative Companies Shaping the

Future

- Innovation and international growth

of a midsized company

- Networking in partnership with

customers, suppliers and universities

- Development and manufacturing of

future - oriented materials and prod-

ucts in modern processing technolo-

gy

*Speaker 13

09:30 a.m.

Presentation

5.3

H. J. Fuhrmann*, Salzgitter AG, Salz-

gitter

Steel – a Material from Europe for

Products from Europe?

- Steel is the no.1 industrial material

- Potentials of the material steel

- Value-added chains stimulate inno-

vative solutions

- The European and German energy,

environmental and industrial policies

– more contradictions than con-

cepts?

- Conclusion

10:00 a.m. Break, Trade Exhibition and Poster

Exhibition

6. Lightweight Design Chairman: W. Volk

TU München

10:30 a.m.

Presentation

6.1

W. Hufenbach*, F. Adam, A. Ulbricht,

Technische Universität Dresden

Systematically Reducing Mass:

Multi-Material Design from Materials

to Products

- Composite materials

- Hybrid design

- Process integration

- Function integration

14 Friday

10:55 a.m.

Presentation

6.2

L. Eckstein*, RWTH Aachen

Steel as the Backbone of Automo-

tive Lightweight Design

- Steel in multi-material solutions

- Conflict of goals: safety – energy

efficiency

- Steel as a green lightweight material

- Examples of use from urban vehicles

to heavy trucks (results of current

research projects)

11:20 a.m.

Presentation

6.3

A. Hauger*, J. Brecht, Mubea Tailor

Rolled Blanks GmbH, Attendorn

Flexible Rolling of Aluminium – an

Innovative Contribution to Automo-

tive Lightweight Design

- Aluminium-Tailor Rolled Blanks

- Process chain development

- Material properties

- Application examples body and

chassis

11:45 a.m.

Presentation

6.4

D. Bailly*, G. Hirt, R. Herkrath,

M. Trautz, RWTH Aachen

Self-Supporting Lightweight Fa-

cades in Stainless Steel Using In-

cremental Sheet Forming

- Individual free form facades

- Design, production and joining

technology using the example of a

prototype building

12:10 p.m. Snack, Trade Exhibition and Poster

Exhibition

*Speaker 15

7. Strip Casting Chairman: H. Palkowski

TU Clausthal

1:00 p.m.

Presentation

7.1

T. Georgi-Maschler*, Hydro Aluminium

Rolled Products GmbH, Bonn

Measures to Increase Productivity at

an Aluminium Twin-Roll Caster

- Status quo of TRC-casters

- Shell cooling

- Roll surface temperature

- Measurement technique

1:25 p.m.

Presentation

7.2

M. Ullmann*, M. Oswald, H.-P. Vogt, R.

Kawalla, TU Bergakademie Freiberg

Properties Development of Twin-Roll

Cast and Hot Rolled Strip of Mg

Alloy AZ31

- Twin-roll cast strip

- Hot rolling

- Thin strip properties

1:50 p.m.

Presentation

7.3

M. Daamen*, M. Vidoni, G. Hirt, RWTH

Aachen

Strip Casting and Processing Tai-

lored Strips and High Manganese

Steels

- Simulation

- Process technology

- Material properties

16 Friday

2:15 p.m.

Presentation

7.4

W. Klos*, L. Ernenputsch, Thyssen-

Krupp Nirosta GmbH, Krefeld

C. Höckling*, J.-U. Becker, Thyssen-

Krupp Steel Europe AG, Duisburg

Innovative Steel Grades Produced

via Strip Casting

- Twin-roller strip casting

- Innovative steel grades

- Blade strip

- Lightweight

- Automotive

2:40 p.m. G. Hirt*, RWTH Aachen

Closing Words

3:00 p.m. Visit at the Department of Ferrous

Metallurgy (IEHK), at the “Zentrum

Metallische Bauweisen“ (zmb) and

at the Institute of Metal Forming

(IBF).

4:00 p.m. Annual Member Meeting of the

“Verein zur Förderung Bildsamer

Formgebung”

5:00 p.m. Alumni Reunion

17

Poster Exhibition / Institute Visits

All research topics of the IEHK and the IBF will be presented during the poster exhibition and the institute visits. The staff of the institutes will gladly answer any of your questions.

Trade Exhibition

The trade exhibition will take place during the colloqui-um in the foyer of the Eurogress, in which more than 20 industrial enterprises and organisations will present information about their products and services.

Research Fields at the IBF

18

Contact Persons

Director of the IBF: Prof. Dr.-Ing. G. Hirt Tel.: +49 241 80-95907 hirt@ibf.rwth-aachen.de

Chief Engineer / Lecturer at the IBF: Dr.-Ing. M. Bambach Tel.: +49 241 80-95914 bambach@ibf.rwth-aachen.de

Department of Bulk Metal Forming Contact: Dipl.-Ing. D. Recker Tel.: +49 241 80-97624 recker@ibf.rwth-aachen.de

Department of Long and Flat Products Contact: M.Sc. T. Romans Tel.: +49 241 80-95945 romans@ibf.rwth-aachen.de

Department of Strip Casting Contact: Dipl.-Ing. M. Daamen Tel.: +49 241 80-93547 daamen@ibf.rwth-aachen.de

Department of Sheet Metal Forming Contact: Dipl.-Ing. H. Voswinckel Tel.: +49 241 80-95910 voswinckel@ibf.rwth-aachen.de

Department Material Modelling Contact: Dipl.-Ing. S. Seuren Tel.: +49 241 80-95916 seuren@ibf.rwth-aachen.de

Field of Research Process Simulation Contact: Dr. rer.nat. M. Franzke Tel.: +49 241 80-95911 franzke@ibf.rwth-aachen.de

19

General Information

Conference Language

The presentations will be held in German and simulta-neously be translated to English. Please contact the conference office, if you want to receive a headphone. The Conference Proceedings will be printed in Ger-man, including an English abstract.

Conference Fee

The conference fees for the 28th ASK Metal Forming

are given in the following table. All fees include taxes.

Category 1 2 3

Days

Date

only Th.,

07.03.

only Fr.,

08.03.

Th./Fr.,

07./08.03.

Industry 600,- € 600,- € 850,- €

VDEh - members,

DGM, University

540,- € 540,- € 790,- €

Early reservations will receive a 100 € discount

when registered before 14th

December 2012.

The service fee for students, who want to attend the

complete conference, is 200 €. Registration is obligato-

ry.

The Conference fee includes:

- Participation at the presentations and visits

- Conference documents (available at the conference

office at the Eurogress Aachen)

- Drinks during the breaks

- Lunch respectively Snack on 7th Mach 2013 respec-

tively on 8th March 2013

- Participation at the reception and evening event in

the Kamin-Saal and Berlin-Saal of the Pullmann Aa-

chen Quellenhof on 7th March 2013

20

Registration

It is recommended to register via the ASK-homepage

www.ask.ibf.rwth-aachen.de

which is possible until the day of the conference.

Registrations after 8th

February 2013 cannot be

included in the participant list.

The Early-Reservation-Discount can only be re-

ceived when registered until 14th

December 2012.

We kindly ask you to transfer the registration fee only

after you received the invoice. Please transfer the

conference fee with the name of the individual partici-

pants to:

Recipient Kasse der RWTH Aachen

Account-No. 2 53 79

Bank Code 390 500 00

Bank

Sparkasse Aachen

Friedrich-Wilhelm-Platz 1-4

52062 Aachen

Reason for

payment

01141-28268-523410.6075 and

name of the participant

IBAN DE 29 3905 0000 0000 0253 79

BIC AACSDE 33

Student rates are valid for students under the age of 28. Please transmit a copy of your student identifica-tion.

In case of cancellation of the registration until

1st February 2013, we will charge a processing fee of

100 €. After that, the entire fee will be charged. A

replacement participant can be registered without any

further charges.

Queries over phone are possible between 8 a.m. and

3 p.m. on +49 241 80-95922 (Marion Köster).

21

Room Reservation

We offer you the chance to reserve a hotel room by

contacting the “aachen tourist service e.V.”. Please

book by using the internet address or telephone num-

ber stated below. Refer to the 28th ASK to book from

the reserved rooms.

aachen tourist service e.v.

PO Box 10 22 51

52022 Aachen

Tel.: +49 241 18029-50 or 51

Fax.: +49 241 18029-30

E-mail: incoming@aachen-tourist.de

Homepage: www.aachen-tourist.de

Online-reservation:

http://www.aachen-congress.de/hotels/ask2013

Please book before 5th February 2013 in order to get a

desired accommodation.

22

Memos