Fraunhofer Institute for Machine Tools and Forming Technology
Fraunhofer Institute for Machine Tools and Forming Technology
Presshärten von Rohren und Profilen

Active media forming

Economic realization of sophisticated designs and complex structural components

Active media-based forming encompasses a variety of processes for shaping tubes, profiles, and sheets. Hydroforming (HF) of tubes and profiles is the most important technology in this group of processes. Both at room temperature, preferably with liquid active media, and at forming temperatures up to 1100 °C using gases, a wide range of materials can be shaped. In addition to the forming temperature, the strain rate is a process parameter to extend technological limits and areas of application. This is particularly true for superplastic forming, which is characterized by low strain rates that, combined with high forming temperatures, allow for forming degrees of several hundred percent.

Temperature also plays a significant role in some process variants. In addition to the classical active media-based hot forming of light metals, a process combination of hydroforming and press hardening has been realized at the Fraunhofer IWU. This approach combines the advantages of structural and material lightweight construction. With hydroforming-press hardening, ultra-high-strength structural components can be manufactured from closed profiles made of manganese-boron steels. Another application of hydroforming is its combination with injection molding in a single tool to produce hybrid components.

Trends

  • Forming of a wide range of materials
  • Forming temperatures from room temperature to over 1100 °C
  • Expanding technological limits and applications through targeted use of strain rate and forming temperature as process parameters
  • Economic production of components and assemblies through combination with or integration of other processes:
    • Heat treatments
    • Injection molding
    • Integration of joining operations

Our range of services

Feasibility Analyses

We are happy to advise you on both the design of new components and the evaluation of existing geometries. We conduct feasibility analyses and assess the technological potential.

Process Planning

The central task in designing manufacturing processes is process planning. We draw on years of experience from numerous industrial and research projects and rely on the capabilities of FEM tools. This enables us to virtually simulate and evaluate processes without having to manufacture tools.

Economic Analysis and Comparison

In addition to technological feasibility, the economic viability of a component design and the corresponding manufacturing process must be examined. With our experience in designing and calculating various process variants, as well as comparing them, we can support you in finding the process that best suits the component and your production environment.

Optimization of Design and Process

Rarely do the initial component design and process planning represent the optimal solution. For this reason, we optimize both until the desired requirements and expectations are met. Depending on the application, we use commercial optimization tools (e.g., OptiSLang) or our own methods and scripts to minimize manual effort.

Simulation

Simulation is a vital tool for us to investigate processes and component designs in advance. In addition to specialized software packages (e.g., PAM2G, AutoForm), we use all-purpose tools (e.g., Ansys, Abaqus, LS-DYNA) and experienced personnel to push beyond existing limits.

Tool Design, Manufacturing, and Try-Out

According to your specifications (standards and guidelines), we design both prototype and production tools for you. Tool manufacturing and try-out can be done in-house or in collaboration with selected external partners.

Prototyping and Analysis

Upon request, we manufacture initial prototypes on our equipment and support you through to series production of the components.

Process Development

For new requirements, we develop new processes or expand existing technologies.

Research topics

 

High-pressure sheet forming

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Hydroforming

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Superplastic sheet metal and tube forming

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Active media forming with pressure pulses

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