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The Fraunhofer IWU ChemnitzDepartment Sheet Metal Forming

Main Fields of action

� sheet metal forming / hot forming

� media and energy based forming technologies

� cutting technologies

� materials testing and characterization

� coupled simulation of forming processes

� development and manufacturing of die systems

Automotive door made of magnesium Hollow camshaft made by hydroforming

Bionicle design of a chair

Innovative LED-street lamp

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The Fraunhofer IWU – Dept. Sheet Metal FormingRange of materials and process conditions

Materials:

� steels: mild steels � stainless steels �high strenght steels � press-hardened steels

� light metals: aluminum � magnesium � titanium

� non-ferrous metals: copper � brass � bronze � niobium

� hybrids: metal foam � hylite � hybrix

� thickness: foils � sheets � solid sheets

Forming conditions:

� forming temperature: room temperature � 1000 °C (0,8*Θs )

� forming pressure: 0 bis 700 MPa (7000 bar)

� strain rates: superplastic 1*10-4 1/s � high speed 1*104 1/s

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The Fraunhofer IWU – Dept. Sheet Metal FormingMaterial testing and characterization

Survey of equipment:

room temperature increased temperatures up to 1000 °C

forming temperature

form

ing speed

norm

al

high

unaxialtension test

maxi bulge test

Tension- Compr. test

biaxialtension test

Strip-Draw-Test

FLC-Test

high speed tension and compression

test

forming andquenchingdilatometer

Laser Flash apparatus

dynamic differential calorimeter

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The Fraunhofer IWU – Dept. Sheet Metal FormingApplicationsTechnologies and application area:

High Speed Cutting and Fine Blanking

Spraycompacted Test Tools

Forming and Joining Technologies for Dissimiliar Materials

Hotforming of Tube / Profiles and Sheet Metal components

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The Fraunhofer IWU – Dept. Sheet Metal FormingCooperation profile

Cooperation profile

� Part design and advisory service - Technological investigations

� Feasibility studies and economic efficiency

� Materials testing, parameter identification and component analysis

� FEM forming and joining simulation

� Component and tooling concepts and optimization

� Tool design and manufacturing

� Tryout and Process optimisation

� Production of prototypes and mini series

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The Fraunhofer IWU – Dept. Sheet Metal FormingCooperation in CORNET-projectsAlready finished CORNET-Projects:

� LorCot – Load-related Design of Coatings for Forming Tools

� ACODEPT – Adv. Coil Design for Electromagnetic Puls Technologies

� ISF-Light – Heat supported Incremental Sheet Metal Forming

Working in CORNET-Projects:

� INCOPI – Inside coated pipes with high fouling resistance

� SENSOFUT – Sensorised Future – Sensor integration in forming tools

� HyBlade – Hydroformed metal blades for meshes of vertical axis wind turbines (VAWT)

� INFIBLANK – Life time increase of tools for fine blanking operations by optimized toll materials and coating systems

� PreFiHy - Prefinished light metal polymer hybrid parts

� SimoPoli - Efficient application of formable powder based lacquer systems for individual products

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The Fraunhofer IWU – Dept. Sheet Metal Forming

You are welcome for further discussion !

CONTACT :

Dipl.-Ing. Thomas Lieber

TEL: +49 371 5397 1212

FAX: +49 371 5397 61212

Mail:

thomas.lieber@iwu.fraunhofer.de

Team of Department Sheet Metal Forming