Fraunhofer Institute for Machine Tools and Forming Technology
Fraunhofer Institute for Machine Tools and Forming Technology

Sheet metal forming

Technologies of the next generation

We develop and implement tool concepts for realizing single-unit production or mass production by applying forming technologies. In addition, our monitoring and control systems ensure stability and reproducibility of the forming processes. Another focus in the display of final component geometries is the technological design and tool design of cutting processes.

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Innovative forming technologies

Sheet metal hot forming of steel, aluminum, magnesium and titanium

Cutting technologies

Surface engineering

  • Tool design – tribological investigation
  • Optimizing the coating adhesion of hybrid laminates

Simulation

Process monitoring

  • Online process monitoring

  • Increasing the stability of manufacturing good parts
  • Saving component weight by using novel materials
  • Processing of difficult-to-form materials
  • Realizing higher model variety by using variable, modular basic tool concepts
  • Increasing component accuracy
  • Forming of hybrid materials

Development of process chains

  • Market analysis
  • Investigation of process chains
  • Process optimization
  • Design of cost- and resource-efficient process route depending on number of pieces, component complexity and plant technology
  • Development of manufacturing concepts
  • Planning and technological dimensioning of processes, tools and machines
  • Recommendations for investments in machines and technologies

Development and evaluation of sheet metal forming strategies

  • Market analysis
  • Feasibility studies
  • Technology development
  • Development of characteristic process values and optimal forming strategies
  • Benchmarking
  • Numerical simulation
  • Manufacturing of prototypes

Quality assurance

  • Process monitoring and control
  • Evaluation of process stability, identification of relevant process parameters and their interactions

Machine technology

  • Hydraulic tryout press EHP4-1600 with multi-point die cushion and high-speed-system (press force: 16,000 kN, table size: 4,000 mm x 2,500 mm)
  • Multi-servopress MSP4-2000-2.5x1.2-400 (4 main drives, maximum compressive force 2,000 kN, ram speed 280 mm/s, table dimensions 2,500 x 1,200 mm)
  • Hydraulic double-column frame press HD 315 (press force: 3,150 kN, table size: 800 mm x 1,000 mm)
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  • Hydraulic double-column press PYZ 250 with multi-point die cushion (press force: 2,500 kN, table size: 1,700 mm x 1,250 mm)
  • Hydraulic C-stand press CLDZ 250 with die cushion (press force: 2,500 kN, table size: 1,060 mm x 780 mm)
  • ....

Software

  • Design: Creo Elements/Pro  (Pro/ENGINEER), CATIA V5, Autodesk®, Inventor®, AutoCAD®
  • Simulation: PAM-STAMP, DEFORM, LS-DYNA, AutoForm, simufact, Abaqus, ANSYS®, ANSYS-CFX, ANSA, FEMM
  • Planning and evaluation of experiments: Cornerstone, Origin, MatLab
  • TOSCA
  • LS-OPT
  • Modern work stations (Windows)
  • Computing cluster (LINUX)

Testing technology

  • Tensile testing machine Zwick 1475 with optical strain rate measurement, high temperature capability of up to 1,100 °C and a maximum force of 100 kN
  • Tensile testing machine Zwick FR 020TN with a maximum force of 20 kN
  • Biaxial tensile testing machine Zwick BX1-FR250SW.A1K with a maximum force of 30 kN (small specimens) and 250 kN (large specimens)
  • Tensile testing machine UTS 20 with vacuum / inert gas oven of up to 1,600 °C
  • High speed tensile testing machine Zwick-HTM 16020, testing speed in tension and compression up to 20 m/s, can be tempered up to 1,000 °C
  • ...