Experimental determination of stress limit curves - comparison of applied technological tests and stamped components by fractographic examinations - Hezler, Christian; Tsoupis, Ioannis; Merklein, Marion; Kasparbauer, M. (Proc. 5th Forming Technology Forum, 2012)
LFT Import::2019-08-05 (1807)

Experimental Determination of Yielding of the Aluminium Wrought Alloy AA6016 for Biaxial Loading - Hußnätter, Wolfgang; Merklein, Marion; Geiger, Manfred (Proceedings of COMA 2007, 2007)
LFT Import::2019-08-05 (1385)

Experimental Determination of Yield Loci for Magnesium Alloy AZ31 under Biaxial Tensile Stress Conditions at Elevated Temperatures - Geiger, Manfred; Merklein, Marion; Hußnätter, Wolfgang; Grüner, Martin (Production Engineering, 2008)
The finite element analysis (FEA) has become one of the most relevant and most important tools in fields of sheet metal forming for designing processes and dimensioning parts. However, reliability and quality of the numerical results strongly depend on the whole FE-model and especially on the modeling of the material behavior, which shows wide impact on calculated stresses and strains of sheet metal parts. Therefore, the experimental determination of characteristic material data concerning anisotropic and temperature-effects is essential. In this paper the influence of temperature on the yielding and the hardening behavior of the magnesium sheet metal alloy AZ31 are investigated for different uniaxial and biaxial stress conditions. For that purpose an experimental setup has been developed at the Chair of Manufacturing Technology (LFT) which enables biaxial tensile testing of sheet metal. Yield loci of AZ31 are determined as a function of temperature and they are based on solely measurement data of the forming process itself. © German Academic Society for Production Engineering (WGP) 2008.
LFT Import::2019-07-29 (294)
Keywords: Computer aided engineering; Material characterization; Yield locus diagram

Experimental Evaluation of Cold Forging Lubricants Using Double-Cup-Extrusion-Tests - Lorenz, Robby; Hagenah, Hinnerk; Merklein, Marion (Materials Science Forum, 2018)
Cold forging processes enable the economical production of high quality components like joints, shafts and gears. The manufactured parts are characterized by improved properties such as hardness, surface quality and fatigue strength. For manufacturing components using cold forging, a comprehensive knowledge regarding the cold forging procedure and its process parameters is needed. One important influencing factor, which needs to be analyzed to use the potential of this kind of processes, is the tribological system, especially the used lubricant. The tribological conditions significantly influence the material flow and thus the workpiece quality. Furthermore, resource efficient and environmentally benign metal forming processes became very important within the last decade. The present study evaluates the resulting tribological conditions and their differences for various cold forging lubricants with and without a zinc phosphate based lubricant carrier. The lubricants are based on molybdenum disulphide, polymers, or both inorganic salts and waxes. The tribological conditions of the different lubricants are investigated using the Double-Cup-Extrusion-Test (DCET) as a laboratory friction test.<br
LFT Import::2019-08-07 (2295)
Keywords: Cold forming; Gear; Lubrication; Steel; Tribology

Experimental Evaluation of the Feasibility and Reproducibility of a Novel Multi-step Forming Process for Cu-OFE Micro Gear Manufacturing Compared to Macro-scale Forming - Rohrmoser, Andreas; Kraus, Martin; Leicht, Miriam; Merklein, Marion (Manufacturing Letters, 2022)
The increasing miniaturization of technical systems leads to a rising demand for micro components. Miniaturized drive systems with geared micro parts or micro gears are applied in various industries. Due to the demand for high production volumes, productive and resource-efficient fabrication is of major importance. Compared to industrially applied manufacturing methods like cutting and metal powder injection, cold forming provides technological, economic and ecological potential for the mass production of micro gears. It enables high productivity and advantageous mechanical properties of the gears. In the macroscopic size range, forming processes are well established in series production of gears. However, in micro-scale, according to the current state of the art, cold forming of modules m < 0.2 mm is not possible due to size effects, high tool loads and handling problems. Within this contribution, a multi-stage forming process for the fabrication of micro gears with a module of m = 0.1 mm is introduced and compared with a conventional forming process on macro-scale with a module of m = 1.0 mm. The use of coil material provides potential for easy handling of the micro parts in a progressive die for the potential application in a high-speed press. In addition, the multi-stage forming achieves a grain alignment, which enhances the formation of the micro gear profile. Based on the comparison between micro- and macro-scale, the performance of the micro process is analyzed with regard to deviations of process force as well as gear quality and possible size effects are identified. The results prove the feasibility of the process chain and the achievement of equivalent part quality and reproducibility compared to macro-scale forming.<br

Experimental Investigation and Numerical Modeling of the Bond Shear Strength of Multi-layered 6000 Series Aluminum Alloys - Herrmann, Jürgen; Suttner, Sebastian; Merklein, Marion (Procedia Engineering, 2017)
The use of high-strength aluminum alloys is one key factor for the realization of lightweight design in industrial applications. Besides alloying, it is possible to produce high-strength sheet materials using the Accumulative Roll Bonding (ARB) process. Based on a repetitive stacking and roll bonding process, multi-layered sheets with a nanocrystalline grain structure are produced. The bond formation is created by a cold welding process due to the high pressure in the rolling gap and cracks in the oxide film of the aluminum sheet material caused by the thickness reduction. The experimental investigation of the bond strength is crucial for the assessment of the formability of the multi-layered sheet material. High bonding quality is necessary in order to prevent failure mechanisms like delamination in subsequent forming operations. Furthermore, a numerical model, which contains discrete layers over the sheet thickness as well as their bonding mechanisms will be implemented in finite element analysis. This enables a process layout for forming operations by the prediction of delamination effects. Within this investigation, an experimental test method is presented to characterize the bond shear strength of multi-layered sheet material. The use of an optical strain measurement system enables the identification of the material behavior over the sheet thickness during the shear test. For this investigation a 16-layered aluminum alloy AA6014 is used. However, the bond shear strength of the last bonded respectively middle layer of the sheet material is investigated. The 16-layered material has 15 bonds over the thickness but the one in the middle has the lowest bond strength as it was only roll bonded once compared to the others, which were rolled at least twice. The bonding mechanisms are modelled using a tiebreak contact formulation in the finite element software LS-DYNA. Concluding, the numerical model is validated by comparison with the experimental results.
EAM Import::2019-03-14

Experimental investigation of a process chain combining sheet metal bending and laser beam melting of Ti-6Al-4V - Butzhammer, Lorenz; Dubjella, Patrick; Huber, Florian; Schaub, Adam; Aumüller, Markus; Baum, Alexander; Petrunenko, Oleksandra; Merklein, Marion; Schmidt, Michael (Lasers in Manufacturing LIM 2017, 2017)
In spite of several advantages such as a great freedom of design, comparatively long process times are a major drawback in additive manufacturing technologies such as laser beam melting (LBM) of metal powder. A strategy to overcome this limitation is to combine additive manufacturing with other promising manufacturing concepts. In this paper, we characterize hybrid components manufactured using a consecutive process chain including warm bending of Ti-6Al-4V sheets and LBM. With the additive process a functional structure is built on top of the bending zone using powder from the same material. As a measure for the connection strength, shear tests were performed. The shear strength is analyzed for both possible process routes of forming and LBM. Therefore a modular clamping device for bent sheets was developed in order to enable simultaneous production of additive parts on several bent sheets with different thicknesses and radii. Results show that the formability of sheets is strongly influenced by the sequence of the process route, while no significant difference in shear strength of the connection was observed, even if the energy density in the LBM process is varied to a large extent. The post heat treatment is discussed as major cause, as homogenization of the microstructure takes place, although the applied temperature is beneath the beta transus temperature.
Keywords: Laser Beam Melting; Additive Manufacturing; Bending; Titanium Alloys

Experimental investigation of direct diamond laser cladding in combination with high speed camera based process monitoring - Scheitler, Christian Josef; Hugger, Florian; Hofmann, Konstantin; Hentschel, Oliver; Bätzler, Tim; Roth, Stephan; Schmidt, Michael (2015)

Experimental investigation of distortion behavior of laser heat treated blanks - Rigas, Nikolaos; Merklein, Marion (Procedia CIRP, 2020)
Aluminum alloys fulfill the growing demands for lightweight applications and are completely recyclable. The use of high-strength aluminum alloys offers the opportunity to replace safety-relevant steel components. Currently, the use of these alloys is limited due to their low formability and high springback during forming at room temperature. The use of tailored blanks with locally adapted material properties is one opportunity to overcome these limitations. By local heat treatment, zones are locally softened and thus crack critical areas during forming can be avoided. At present, blanks with tailored properties are not used extensively. One reason for this is component distortion due to thermal stress, which makes handling the heat-treated sheets more difficult. Aim of this study is the identification and reduction of thermally caused component distortion. Therefore, in this paper the influence of the initial material condition, the sheet thickness as well as the laser spot size on the distortion behavior is investigated.
CRIS-Team Scopus Importer:2020-10-30
Keywords: Distortion; High-strength aluminum; Tailor heat threated blanks

Experimental investigation of heat-treated aluminum profiles - Merklein, Marion; Graser, Matthias; Lechner, Michael (Key Engineering Materials, 2015)
Tailor Heat Treated Profiles (THTP) are profiles that exhibit local different mechanical properties optimized for a subsequent forming operation. The property distribution is realized by short term heat treatment before a forming operation. Based on the interaction of soft and hard areas the material flow can be improved and the formability can be enhanced. Prerequisite for a successful application of the technology is a comprehensive material characterization. Therefore, within this paper the influence of short term heat treatment on the mechanical properties of profiles will be presented. In particular, different heating technologies based on heat conduction and laser radiation are compared. Based on the results, a process window will be derived. All investigations were performed using the precipitation hardenable aluminum alloy EN AW 6060.
LFT Import::2019-07-29 (2112)
Keywords: Aluminum profiles; Characterization; Tailored heat treatment

Experimental investigation of the contact phenomena in cold forging - Geiger, Manfred; Engel, Ulf; Niederkorn, Sorin; Pfestorf, Markus (Production Engineering, 1996)
LFT Import::2019-07-15 (640)

Experimental investigation of Ti-6Al-4V with a biaxial tensile test setup at elevated temperature - Merklein, Marion; Suttner, Sebastian; Schaub, Adam (Key Engineering Materials, 2014)
The requirement for products to reduce weight while maintaining strength is a major challenge to the development of new advanced materials. Especially in the field of human medicine or aviation and aeronautics new materials are needed to satisfy increasing demands. Therefore the titanium alloy Ti-6Al-4V with its high specific strength and an outstanding corrosion resistance is used for high and reliable performance in sheet metal forming processes as well as in medical applications. Due to a meaningful and accurate numerical process design and to improve the prediction accuracy of the numerical model, advanced material characterization methods are required. To expand the formability and to skillfully use the advantage of Ti-6Al-4V, forming processes are performed at elevated temperatures. Thus the investigation of plastic yielding at different stress states and at an elevated temperature of 400°C is presented in this paper. For this reason biaxial tensile tests with a cruciform shaped specimen are realized at 400°C in addition to uniaxial tensile tests. Moreover the beginning of plastic yielding is analyzed in the first quadrant of the stress space with regard to complex material modeling.
LFT Import::2019-07-29 (2018)
Keywords: Formability; High performance metals; Sheet metal forming

Experimental investigation of tool-sided surface modifications for dry deep drawing processes at the tool radii area - Krachenfels, Kim; Rothammer, Benedict; Tremmel, Stephan; Merklein, Marion (Procedia Manufacturing, 2019)
In conventional deep drawing processes lubricants are applied to reduce friction and wear. Demands for increased sustainability, environmental protection and resource efficiency motivate the realization of lubricant-free forming processes. The direct toolworkpiece contact during dry deep drawing leads to changed tribological conditions. Especially in the areas of increased normal and shear stresses, such as the die radius, the dry contact causes an increased risk of wear and damage to the sheet surface. A wellknown approach to face the challenges of dry deep drawing of steel sheets and aluminum alloys is the application of amorphous carbon based coatings on the tool surfaces. Within this study the tribological behavior of conventional and modified tool surfaces at the critical radii area is investigated with a strip bending rotation test. In this test, the friction coefficient is determined based on the relative movement between a rotating test cylinder and a sheet-metal strip bent in a die. For the tribological tests the sheet materials AA6014, AA5182 and zinc coated DC04 are applied. The modification of the tool sided surface was achieved by applying ta-C and a-C:H coatings to the test cylinder. In addition to tests with coated surfaces, tests with uncoated tools are carried out for reference. By analyzing the resulting friction coefficients for the different sheet materials, the suitability of ta-C and a-C:H coatings for dry deep drawing processes is evaluated comparatively. In order to investigate cause-effect relations as well as wear mechanisms, the tool and workpiece surfaces are characterized before and after testing.<br
Keywords: Dry Deep Drawing; Tribology; Carbon Based Coatings

Experimental investigations of processing the high carbon cold-work tool steel 1.2358 by laser metal deposition for the additive manufacturing of cold forging tools - Hentschel, Oliver; Scheitler, Christian Josef; Fedorov, Aleksandr; Junker, Daniel; Gorunov, Andrey; Haimerl, A.; Merklein, Marion; Schmidt, Michael (Journal of Laser Applications, 2017)
In the field of tool making, Laser Beam Melting of metals has been already used to fabricate injection moulds with complex inner cooling channels made out of the low-carbon maraging tool steel X3NiCoMoTi18-9-5 (1.2709). Furthermore, laser metal deposition (LMD) is an established technology for the repair of worn-out tools and the deposition of wear resistance coatings based on metal matrix composites. However, at the moment, the processing of high-carbon tool steels for the additive manufacturing of complete cold forging tools has only been investigated to a limited extent. Within the scope of the presented research, the processing of the high-carbon cold-work tool steel 60CrMoV18-5 (1.2358) by LMD is analyzed in detail. In this context, geometrically simple cuboidal structures are directly generated on dissimilar substrate plates made out of the hot-work tool steel X37CrMoV5-1(1.2343) via the application of various process parameter combinations. The manufactured cuboidal structures are metallographically prepared and subsequently analyzed with respect to substrate bonding, relative density, defect formation, microstructure, chemical composition, and microhardness. In this context, the influence of the particle size distribution of the used tool steel powder on the LMD process itself and the resulting relative density are extensively researched. For this purpose, high-speed camera measurements of the powder particle stream were conducted in order to determine both the powder particle stream diameter and the lateral powder particle distribution with regard to the distance z from the powder nozzle. Furthermore, the influence of an additional substrate preheating (maximum preheating temperature of 400 °C) on the resulting microstructure and hardness of the additively generated samples is the subject of the presented investigations.
CRIS-Team Scopus Importer:2022-06-05

Experimental investigations of processing the high carbon cold-work tool steel 1.2358 by LMD for the additive Manufacturing of cold forging tools - Hentschel, Oliver; Scheitler, Christian Josef; Fedorov, Aleksandr; Junker, Daniel; Gorunow, Andrej; Haimerl, Andreas; Merklein, Marion; Schmidt, Michael (Journal of Laser Applications, 2017)
LFT Import::2019-07-29 (2266)

Experimental investigations on a process adapted material testing method for hydroforming of tubular components - Reblitz, Jonas; Merklein, Marion (SheMet2025, 2025)
In the automotive sector, an important strategy for reducing CO2 emissions is lightweight construction. In this regard, body-in-white parts offer a high potential for weight reduc-tions by substituting conventional steel parts with tubular, aluminum-based components. Due to their high strength-to-weight-ratio and high crashworthiness, tube profiles are often used as safety-relevant car body components. As lightweight design becomes increasingly important, complex part geometries are required, which can be realized by hydroforming. Especially for structural components, an exact determination of the material properties is necessary, in order to achieve a high prediction accuracy of FE-simulations. Thus, a failure-free component production has to be enabled. However, due to a varying stress and strain state, the tensile test according to DIN EN ISO 6892 as a standard characterization method is only insufficiently suitable for the characterization of tube profiles for a hydroforming process. For this purpose, a new testing method has been developed and investigated within this paper, which provides new insights regarding the material behavior of tubular components. The testing-rig is based on a bulge test, which reproduces the stress and strain state of a hydroforming process. By comparing the results of the material characterization with those of a tensile test, the differences in the mechanical properties depending on the testing method are evaluated. During the test, the surface strains and the internal pressure are varied and recorded. Based on these findings, a more accurate prediction of FE-simulations is aspired in future research wor
Keywords: Hydroforming; Aluminum; Tube Bulge Test

Experimental investigations on high-precision microcutting of copper foils with microfabricated silicon punches - Hildering, Sven; Becsi, L.; Engel, Ulf; Merklein, Marion; Mescheder, U. (Proc. 12th Int. Conf. European Society for Precision Engineering and Nanotechnology, 2012)
The miniaturisation of metallic parts is considerable in various industrial sectors. This trend leads to a demand for decreasing tool dimensions. This study shows the application of monocrystalline silicon as tool material for etched punches used for microcutting of thin copper foils, as etching is a common method in microsystems technology for the economical fabrication of thin vertical structures with a high surface quality. Cutting experiments in a specially designed test rig show the applicability of silicon for microcutting of copper foils and the effect of tool wear on the punching force. The workpiece quality is characterised by a large burnish area of the sheared edges.
LFT Import::2019-08-05 (1804)

Experimental Setup for Determination of Yield Loci - Demands of Accuracy - Hußnätter, Wolfgang; Geiger, Manfred (Proceedings of the 4th JSTP International Seminar on Precision Forging, 2006)
LFT Import::2019-08-05 (1260)

Experimental Study of a Full Forward Extrusion Process from Metal Strip - Merklein, Marion; Stellin, Tommaso; Engel, Ulf (Key Engineering Materials, 2012)

Experimental Study of a Microforging Process of Parallel Ribs from Metal Strip - Stellin, Tommaso; Engel, Ulf; Merklein, Marion (Proc. 4M/ICOMM2015 Conf., 2015)
LFT Import::2019-08-05 (2100)

Experimental study of the potential for extending the process limits in multi-stage forming of micro gears from sheet metal by a local short-term laser heat treatment - Leicht, Miriam; Kraus, Martin; Rohrmoser, Andreas; Merklein, Marion (Materials Research Proceedings 2023, 2023)
Cold forming of micro gears is currently not possible for modules m < 0.2 mm due to the occurrence of high tool stresses, handling problems and size effects. A multi-stage process chain of micro bulk forming from sheet metal offers the potential to solve these challenges. However, the industrial applicability is limited due to material efficiency. Against this background, the aim of this research work is an improvement of the material utilization as well as a further reduction of the tool stresses. Therefore, the influence of different heat treatment strategies as well as the materials copper Cu-OFE and brass CuZn30 are analyzed. Thus, a local laser heat treatment and a global heat treatment of the blanks are investigated. The focus of this research work is on the first process stage, pin extrusion, which is used for forming of the wheel blank. Since this process setup provides the material for the further forming stages, it has a huge influence on the material efficiency and on the forming of the gearing in the second process stage. Therefore, the component and process properties are evaluated to assess the influence of the measures. The results prove higher material efficiency at a similar tool stress by using local short-term heat treatmen

Experimental Study on Joining by Forming of HCT590X+Z and EN-AW 6014 Sheets Using Cold Extruded Pin Structures - Römisch, David; Kraus, Martin; Merklein, Marion (Journal of Manufacturing and Materials Processing, 2021)
Due to stricter emission targets in the mobility sector and the resulting trend towards lightweight construction in order to reduce weight and consequently emissions, multi-material systems that allow a material to be placed in the right quantity and in the right place are becoming increasingly important. One major challenge that is holding back the rapid and widespread use of multi-material systems is the lack of adequate joining processes that are suitable for joining dissimilar materials. Joining processes without auxiliary elements have the advantage of a reduced assembly effort and no additional added weight. Conventional joining processes without auxiliary elements, such as welding, clinching, or the use of adhesives, reach their limits due to different mechanical properties and chemical incompatibilities. A process with potential in the field of joining dissimilar materials is joining without an auxiliary element using pin structures. However, current pin manufacturing processes are mostly time-consuming or can only be integrated barely into existing industrial manufacturing processes due to their specific properties. For this reason, the present work investigates the production of single- and multi-pin structures from high-strength dual-phase steel HCT590X + Z (DP600, t(0) = 1.5 mm) by cold extrusion directly out of the sheet metal. These structures are subsequently joined with an aluminium sheet (EN AW-6014-T4, t(0) = 1.5 mm) by direct pin pressing. For a quantitative evaluation of the joint quality, tensile shear tests are carried out and the influence of different pin heights, pin number, and pin arrangements, as well as different joining strategies on the joint strength is experimentally evaluated. It is proven that a single pin structure with a diameter of 1.5 mm and an average height of 1.86 mm achieves a maximum tensile shear force of 1025 N. The results reveal that the formation of a form-fit during direct pin pressing is essential for the joint strength. By increasing the number of pins, a linear increase in force could be demonstrated, which is independent of the arrangement of the pin structures.
CRIS-Team WoS Importer:2021-04-30

Experimental study on the flow behavior during hot forming and quenching of the high-strength aluminum alloy AA6111 - Degner, Julia; Horn, Alexander; Merklein, Marion (XXXVI. Verformungskundliches Kolloquium, 2017)
LFT Import::2019-08-05 (2221)

Experimental study on the warm forming and quenching behaviour for hot stamping of high-strength aluminum alloys - Degner, Julia; Horn, Alexander; Merklein, Marion (Journal of Physics: Conference Series, 2017)
LFT Import::2019-08-05 (2228)

Experimentelle Ermittlung der Formgebungsgrenzen metallischer Werkstoffe unter reiner Scherung - Merklein, Marion; Kuppert, Andreas; Biasutti, Manfredi (12. Workshop - Simulation in der Umformtechnik (26.03.2009), 2009)
LFT Import::2019-08-05 (197)

Experimentelle Untersuchung des Bruchverhaltens von Hartmetallen für Fließpreßmatrizen - Wissmeier, Hans-Jürgen; Engel, Ulf; Geiger, Manfred (Draht, 1990)
LFT Import::2019-07-15 (742)

Experimentelle Untersuchung des zweiachsigen Spannungszustands im Kreuzzugversuch zur Identifikation von Werkstoffmodellen für die Finite-Elemente Simulation - Suttner, Sebastian; Merklein, Marion (Tagungsband Werkstoffprüfung, 2013)
LFT Import::2019-08-05 (1920)

Experimentelle Untersuchungen zum Laserstrahl-Punktschweißen metallischer Folien mittels kurzer Laserimpulse - Prechtl, Martin; Schmidt, Michael; Barth, J. (LEF 2004, Laser in der Elektronikproduktion und Feinwerktechnik, 2004)
LFT Import::2019-07-16 (1033)

Ex-situ and in-situ investigations of the microstructural evolution of AA6082 aluminum alloy during heat treatment - Lypchanskyi, Oleksandr; Rigas, Nikolaos; Korpala, Grzegorz; Merklein, Marion; Prahl, Ulrich (Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing, 2023)
The present study investigated the microstructural evolution of AA6082 aluminum alloy using ex-situ and in-situ methods. Microstructural characterization was performed for the individual steps of the heat treatment parameters. To identify the morphology and kinetics of changes in precipitation and grain, the microstructure of the alloy was examined using scanning electron microscopy/electron backscatter diffraction in combination with energy dispersive X-ray spectrometry. Analysis of the microstructural changes revealed coarser β-Mg2Si nucleation and growth activity, but it showed no changes related to grain growth or α-Al(FeMn)Si precipitation activity. Additionally, the formation of rod-shape β' precipitates was evaluated. Higher temperature promoted the growth and increase in length of β' rods and the appearance of β' rods outside of contact with the intermetallic precipitation. The influences of different isothermal holding temperatures on the relative change in signal velocity generated by a laser ultrasonics for metallurgy (LUMet) system were evaluated. The strong correlation between the findings of microstructural analysis and the results derived from ultrasonic measurement confirmed the efficacy of the novel in-situ model test for predicting microstructural change
Keywords: Aluminum alloy; Precipitation behavior; Ultrasonic signal; Mg2Si

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements - Pilz, Florian; Henneberg, Johannes; Merklein, Marion (Manufacturing Review, 2020)

Fabrication and Characterization of Laser Beam Melted Ti-6Al-4V Geometries on Sheet Metal - Schaub, Adam; Ahuja, Bhrigu; Karg, Michael; Schmidt, Michael; Merklein, Marion (Proceedings DDMC 2014 Fraunhofer direct digital Manufacturing conference, 2014)
Laser beam melting is a well-established additive manufacturing process for fabricating fully dense 3-dimensional structures from micro size metal powders using a high intensity laser beam. Ti-6Al-4V is a state of the art alloy used in the Laser Beam Melting process. For light weight applications specifically within the aerospace and medical industry, it is essential to understand and evaluate the interaction of additively manufactured structures with conventionally fabricated sheet metal. The following paper illustrates steps that have been taken in this direction. The paper details various process related modifications undertaken in order to achieve the appropriate mechanical properties of the Laser Beam Melted structure on pre-fabricated thin sheet metal. In order to evaluate mechanical properties, the tensile bond strength is determined. Further the paper also takes into account the development of parameters and scanning strategies for processing Ti-6Al-4V on Realizer SLM 50. An important focus of the conducted experiments is the application of additional strategies in order to reduce the effect of factors, such as oxidation and temperature gradient in the initial layers, adversely affecting the mechanical properties of the hybrid structure. One of the future applications of this initial research could be the fabrication of intricate elements using laser based additive manufacturing processes on sheet metal in order to develop ultra-light weight structures for potential use in critical high technology application
LFT Import::2019-08-05 (1981)
Keywords: Additive Manufacturing; Laser Beam Melting; Sheet Metal; Ti-6Al-4V

Fabrication of highly precise fiber optical array products by use of laser based micro alignment - Zimmermann, M.; Schaefer, L.; Rank, M.; Schmidt, Michael; Roth, Stephan (4M 2007, Third International Conference on Multi-Material Micro Manufacture, 2007)
LFT Import::2019-08-05 (1475)

Fabrication of three-dimensional photonic crystals with tunable photonic properties by biotemplating - Van Opdenbosch, Daniel; Johannes, Maren; Wu, Xia; Fabritius, Helge; Zollfrank, Cordt (Photonics and Nanostructures-Fundamentals and Applications, 2012)
Photonic crystals with tunable D-surface structures for possible high-temperature gas- and temperature-sensing applications were prepared by a biotemplating method. This included infiltrating colored scales of the beetle Entimus imperialis with an organopolysiloxane mixture followed by simultaneous combustion of the template and calcination of the cured organopolysiloxane. A high-yield inorganic silica-based replica of the original structure was obtained, which is capable of withstanding temperatures up to 600 °C. Light- and scanning electron microscopy combined with focused ion beam milling showed a precise replication of the whole scales and their internal D-surface structure. Fourier-transform infrared spectroscopy and X-ray diffraction analysis confirmed the complete curing of the organopolysiloxanes and their transformation into amorphous silica during calcination. The dielectric constant of the manufactured materials determined by Abbé refractometry was ε = 2.3180 and used to perform band structure calculations utilizing the plane wave expansion method. By changing the chain length and degree of crosslinking of the organopolysiloxane precursor mixture, the lattice parameters and filling factors, and therefore the photonic properties of the replicas, could be tuned. © 2012 Elsevier B.V. All rights reserved.
LFT Import::2019-07-29 (1810)
Keywords: Biotemplating; D-surface; Inorganic; Photonic; Sensing application; Tunable

Failure behavior of different sheet metals after passing a drawbead - Schmid, Harald; Hetz, Peter; Merklein, Marion (47th SME North American Manufacturing Research Conference, NAMRC 47, Pennsylvania, USA, 2019)
LFT Import::2019-08-05 (2364)

Fast and Flexible Generation of Conductive Circuits - Amend, Philipp; Hentschel, Oliver; Scheitler, Christian Josef; Baum, Marcus; Heberle, Johannes; Roth, Stephan; Schmidt, Michael (Journal of Laser Micro Nanoengineering, 2013)
The functional and geometrical requirements to electronic, optoelectronic and mechatronic devices have significantly increased during the last years. Within the scope of the development and the fabrication of such components a very important aspect is the fast and flexible generation of conductive circuits respectively structures on work-pieces of various dimensions and materials. The presented work gives an overview about three promising laser-based approaches to generate microscopic and macroscopic circuits as well as conductive layers with a thickness in the order of a few hundred nanometers. In addition to processes for the fabrication of conductive structures laser-based soldering of piezo-composites is investigated.
Keywords: conductive circuits; ITO nanoparticles; stereolithography; ADDIMID technology; Molded Interconnect Device; Laser-Beam-Melting; laser-based soldering; piezo-composites

Fast, problem specific approaches for the evaluation of laser beam propagation in process planning - Hagenah, Hinnerk; Plettke, Raoul; Klämpfl, F. (Proceedings of the 6th CIRP International Conference on Intelligent Computation in Manufacturing Engineering, 2008)
LFT Import::2019-08-05 (146)

Fatigue Behavior of Cemented Carbide Based Forming Tools - Andreas, Kolja; Merklein, Marion; Engel, Ulf (Proc. 18th Plansee Seminar, 2013)
LFT Import::2019-08-05 (1893)

Fatigue Dependent Design of Hard Coated Cold Forging Tools - Hinsel, Christian (2nd JSTP International Seminar on Precision Forging, 2000)
LFT Import::2019-08-05 (813)

Fatigue testing of cold forging tools using elastomer compression - Killmann, Martin; Merklein, Marion (CIRP Annals - Manufacturing Technology, 2023)
Cold forging is an ecological production technology for high-strength metal parts. Tool fatigue is the most significant constraint preventing the enhancement of process limits towards complex part geometries. To better analyse tool fatigue, a test method for dies under high inner pressure is researched. The load usually transmitted by the workpiece is applied by compression of elastomers. Results show that the test is able to accurately model the fatigue behaviour of forging tools including crack propagation and the influence of prestressing systems. Compared to conventional fatigue tests, the analysis of different reinforcements and tool geometries is enabled. <
Keywords: Cold Forming; Die; Fatigue

Fatique of PVD and CVD Coated Tool Steel. - Geiger, Manfred; Hinsel, Christian (Proc. of the 29th Plenary Meeting of the International Cold Forging Group (1996), 1996)
LFT Import::2019-08-05 (644)

FE-analysis based optimization of time, costs and quality with the consideration of stochastic process characteristics - Koch, Johannes Peter Karl; Völkl, Ralf; Engel, Ulf (Proceedings of the 12th International Conference Metal Forming, 2008)
LFT Import::2019-08-05 (328)

FE-Analysis Based Prediction of Tool Life in Cold Forging With the Consideration of Stochastic Process Characteristics - Geiger, Manfred; Engel, Ulf; Völkl, Ralf (Production Engineering - Annals of the WGP, 2005)
LFT Import::2019-08-05 (1216)

FE-Analysis for the Double Blank Hydroforming of Complex Structures - Vahl, Meik; Celeghini, Martino; Geiger, Manfred (Proceedings of the Numsheet 2002, 2002)
LFT Import::2019-08-05 (1671)

Featrue Extraction for Advanced Control of Flexible Forming Processes - Hutterer, Angelika; Menzel, Thomas; Otto, Andreas; Müller, G. (Proceedings of the 6th International Fall Workshop, Vision, Modeling, and Visualization, 2001)
LFT Import::2019-08-05 (908)

FE-Based Modeling of Interactions Between Cold Forging Process, Tooling System and Force Controlled Press - Kroiss, Thomas; Engel, Ulf (ICIT&MPT 2009, Proc. of the 7th Int. Conf. on Industrial Tools and Material Processing Technologies, Oktober 4-7, Ljubljana, Slovenia, 2009)
LFT Import::2019-08-05 (498)

FE-based study of the cutting operation within joining by forming of dissimilar materials using shear-clinching technology - Müller, Martin; Hörhold, Réjane; Meschut, Gerson; Merklein, Marion (Advanced Materials Research, 2015)
LFT Import::2019-07-29 (2109)

FE-basierte Prozess- und Werkzeugauslegung zur Herstellung von Hochleistungsbauteilen mit dem Ziel einer gezielten Einstellung von Bauteileigenschaften - Merklein, Marion; Engel, Ulf; Noneder, Johannes; Zimmermann, Andrea (Tagungsband 13. RoundTable - Simulation in der Umformtechnik, 2012)
LFT Import::2019-08-05 (1806)

Fehlertolerante Fügeprozesse im automobilen Umfeld - Schmidt, Michael; Otto, Andreas; Albert, F.; Dörfler, Stephan Manuel; Grimm, A.; Kägeler, C. (Robuste, verkürzte Prozessketten für flächige Leichtbauteile. Tagungsband zum Industriekolloquium des SFB 396, 2006)
LFT Import::2019-08-05 (1279)

Feinblechprüfung mit magnetinduktiven Prüfverfahren - Schwind, Michael; Engel, Ulf; Geiger, Manfred (DVM-Berichtsband der Tagung Werkstoffprüfung 1994 in Bad Nauheim, 1994)
LFT Import::2019-08-05 (623)

FEM-gestützte Beanspruchungsanalyse - Erhöhung der Lebensdauer von Kaltmassiv-Umformwerkzeugen - Völkl, Ralf; Schafstall, H. (Umformtechnik, 2004)
LFT Import::2019-07-16 (1039)

FEM-gestützte Prozessbetrachtung des Direkten Metalllaserstrahlsinterns - Niebling, Frank; Otto, Andreas (Idee-Vision-Innovation, 2001)
LFT Import::2019-07-15 (899)

FEM Simulation of Fatigue Crack Growth in Cold Forging Dies. - Engel, Ulf; Hänsel, Matthias (Advanced Technology of Plasti¬city 1990, Proc. of the 3rd Int. Conf. on Technology of Plasticity, 1990)
LFT Import::2019-08-05 (1951)

FEM Simulation of Mixed-Mode Fatigue Crack Growth in Metal Forming Tools - Hänsel, Matthias; Engel, Ulf; Geiger, Manfred (Mixed Mode and Fatigue Fracture ESIS 14, 1993)
LFT Import::2019-08-05 (420)

FE-Reliability Simulation of Laser Joined Contacts in Electronics Production - Fleckenstein, Marc; Komlodi, Attila (Proceedings of the 3rd International Conference on Benefiting from Thermal and Mechanical Simulations in (Micro)-Electronics, 2002)
LFT Import::2019-08-05 (1713)

Fertigung funktionsoptimierter Bauteile beim Presshärten - Horn, Alexander; Merklein, Marion (Tagungsband zum 13. Erlanger Workshop Warmblechumformung, 2018)
LFT Import::2019-08-05 (2330)

Fertigung innovativer Bauteile aus hochfesten Stählen: Biegen und Schneiden – Risse vermeiden - Merklein, Marion; Tsoupis, Ioannis; Hildering, Sven (Zukunftstechnologien in Bayern - Neue Materialien, Verfahren und Produkte, 2012)
LFT Import::2019-07-29 (206)

Fertigungsaspekte zur umformtechnischen Herstellung von Bauteilen aus Magnesiumblech für den Fahrzeugbau - Geiger, Manfred; Merklein, Marion; Hecht, Joachim; Stich, A. (Tagungsband EFB-Kolloquium 2006 "Konstruktionskonzepte der Gegenwart und Zukunft - Herausforderungen an die Blechbearbeitung", 2006)
LFT Import::2019-08-05 (1271)

Fertigungsmethoden - Lechner, Michael; Böhm, Wolfgang; Merklein, Marion; et al. (Konstruktion, 2013)
CRIS-Team Scopus Importer:2024-02-29

Fertigungsplanung in der Umformtechnik - Montagequalität von Werkzeugen - Putz, Alexander; Engel, Ulf (Uni-Kurier-Magazin, 2005)
LFT Import::2019-07-16 (1133)

Fertigungsqualität beim 3D-Laserstrahlschweißen von Blechformteilen - Schultz, Markus (Friedrich-Alexander-Universität Erlangen-Nürnberg, 1997)
Within this thesis the quality of 3D laser welds along contours with small radii at shaped sheet metal parts has been investigated and documented by significant examples. These results were applied to establish design guidelines for laser welding of shaped sheet metal parts. The three most relevant joint geometries for laser welding of sheets in car body production have been investigated during the experiments: Butt weld, lap weld and lap fillet weld. To evaluate the weld quality of lap and lap fillet welds quality levels for imperfections for these joint geometries had to be defined. Shaped sheet metal workpieces - simple, bended parts and complicated deep drawn car body parts - were welded by the application of different processing strategies - some of them already known and others developed during the investigations. The quality of the welding results was evaluated using the above mentioned quality levels. Good weld quality at all welded parts even at complicated parts like small radii could be achieved by the application of suitable processing strategies. The experiments were performed using a 5-axis gantry machine with a 2.2kW CO2-Laser and a 6-axis industrial robot with a 1kW Nd:YAG-Lase

Fertigung von Prototypen und Werkzeugelementen durch iteratives Paketieren und anschließendes Endfügen von Stahlfolien - Prechtl, M.; Niebling, Frank; Otto, Andreas (Tagungsband der 7. Internationalen Kolloquiums Hart- und Hochtemperaturlöten und Diffusionsschweißen (LöT), 2004)
LFT Import::2019-08-05 (1029)

FE-Simulation des selektiven Laserstrahlsinterns von Metallpulver - Niebling, Frank; Otto, Andreas; Geiger, Manfred (LaserOpto, 2000)
LFT Import::2019-07-15 (795)

FE-Simulation des Werkzeugversagens von Fließpreßmatrizen - Geiger, Manfred; Hänsel, Matthias (Kaltmassivumformung Cold Forging (8. Int. Kongress Kaltumformung Nürnberg), 1990)
LFT Import::2019-08-05 (726)

FE Simulation of Laser Assisted Bending - Pitz, Matthias; Merklein, Marion (Sheet Metal 2005, Proceedings of the 11th International Conference on Sheet Metal, 2005)
Steel has a long tradition and is used in nearly every application. In order to be able to compete with other lightweight materials over and over again new steel grades are developed. Interesting steel grades, which are especially suitable for the lightweight construction in the automotive industry, are the multi-phase steels. Multi-phase steels reach already yield strengths over 1000 MPa. This is a challenge for the production engineering. Drawing, forming and cutting tools must be stiff and hard and/or coated, lubricants have to decrease friction to avoid damages induced by the high surface pressures. The designers have to consider the small forming capability by large radii or reduced drawing depths. To overcome these disadvantages new, innovative forming processes, e.g. laser assisted bending or roll forming, have to be developed. In the forming technique it is known that the forming limits can be increased by warm forming. But the conventional heating systems may cause unwanted changes of the material regarding to the structure and the mechanical properties. In the case of multi-phase steels e.g. the hard phases martensite and bainit can be transformed into ferrite and therefore the yield stresses can be changed clearly. In contrast to this laser assisted bending minimizes structural changes due to the local heating of the forming area. Beside the advantage, that only a small area of the bending part is exposed with a thermal load, the heating up with the laser permits high heating rates and also a controlling of the heating and cooling rates, so that the heating and cooling can be adapted to the material and its properties. In the context of this paper parameter studies with FE simulations of the laser assisted bending process are presented.
LFT Import::2019-08-05 (1173)
Keywords: Bending; Simulation; Steel

FE-Simulation of Microforming Process Applying a Mesoscopic Model - Geißdörfer, Stefan; Engel, Ulf; Geiger, Manfred (International Journal of Machine Tools and Manufacture, 2004)
LFT Import::2019-07-16 (1060)

FE-Simulation of the heat transfer by defined cooling conditions during the hot stamping process - Svec, Thomas; Grüner, Martin; Merklein, Marion (Key Engineering Materials, 2011)
LFT Import::2019-07-29 (1642)
Keywords: Heat transfer; Hot stamping; Numerical simulation; Tailored tempering

FE-simulation of the Selective Laser Sintering Process of Metallic Powders - Niebling, Frank; Otto, Andreas (LANE 2001, Laser Assisted Net Shape Engineering 3, 2001)
LFT Import::2019-08-05 (900)

Festakt 25 Jahre Institut für Maschinenbau der Universität Erlangen-Nürnberg. Mit Laudatio und Festvortrag anlässlich der Ehrenpromotion von K.-D. Bouzakis durch die Technische Fakultät - Kreis, Oliver; Geiger, Manfred; Gaus, Ingrid (2007)

Fiber Orientation Mechanism of Continuous Fiber Reinforced Thermoplastics Hybrid Parts Joined with Metallic Pins - Popp, Julian; Kleffel, Tobias; Römisch, David; Papke, Thomas; Merklein, Marion; Drummer, Dietmar (Applied Composite Materials, 2021)
Continuous Fiber Reinforced Thermoplastic (CFRT) hybrid parts offer interesting possibilities for lightweight application, which can exceed the capabilities of mono material metal or CFRT parts. In this case, the joining technology oftentimes is the limiting factor. This study investigates a joining operation with metal pin structures which are additively manufactured via powder bed fusion featuring different diameters and tip geometries, which are inserted into the locally infrared heated CFRT part. The resulting fiber rearrangement is assessed using transmitted light microscopy, confocal laser scanning microscopy as well as micro-computer-tomography. It could be shown that for all assessed pin variants a similar distinct fiber displacement can be seen and that the pin diameter has a significant effect on the resulting fiber orientation with smaller pin diameters being advantageous because of gentle fiber displacement and reduced undulation. The tip geometry has only minor effect on the fiber orientation. Especially in the X/Y plane no systematic influence of the tip geometry on the fiber displacement could be observed. Based on the gained insights a three-stage model of the fiber orientation processes is proposed.
CRIS-Team Scopus Importer:2021-05-07
Keywords: Continuous fiber reinforced thermoplastics; Fiber orientation; Hybrid part; Joining; Organo sheet; Pin

Finite-Element basierte Auslegung funktionsoptimierter Bauteile im Tailored Tempering Prozess - Svec, Thomas; Merklein, Marion (6. Erlanger Workshop Warmblechumformung, 2011)
LFT Import::2019-08-05 (1773)

Finite Elemente Modelling of Resistance Spot Welding - Komlodi, Attila (Proceedings of the 3rd GTE/MhtE/DVS International Conference on Welding, 2000)
LFT Import::2019-08-05 (819)

Finite Elemente Simulation dünnster Verpackungsstähle: Entwicklung einer geeigneten Charakterisierungs- und Validierungsstrategie - Knieps, Fabian (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2023)
Zur Reduzierung von CO2 Emissionen werden immer höher festere Verpackungsstähle entwickelt, die den Einsatz dünner Blechdicken ermöglichen. Um den hierdurch wachsenden Herausforderungen an die Produkt- und Prozessauslegung gerecht zu werden, bieten numerische Simulationen großes Potential. Die Abbildung des Materialverhaltens in der Simulation bedarf der Beschreibung einer Fließkurve sowie des anisotropen plastischen Materialverhaltens in Form von Fließortmodellen. Aufgrund der Charakteristik von höher festen Verpackungsstählen mit hohen Nachwalzgraden und starken Alterungserscheinungen, war die Ermittlung der relevanten Kennwerte bisher nicht möglich. Die Arbeit beschäftigt sich daher mit der Erarbeitung einer Strategie zur Charakterisierung von Verpackungsstählen für die FE-Simulation. Die Verfestigungsbeschreibung erfolgte über die Optimierung des Zugversuchs, sowie die Verwendung hydraulischer Tiefungsversuche. Die Beschreibung des anisotropen plastischen Materialverhaltens fokussierte sich neben der Beschreibung des ersten Fließortquadranten vor allem auf die r-Wert- Ermittlung durch inverse Modellierung. Die vorgestellten Methoden wurden genutzt, um Materialmodelle für drei verschiedene Verpackungsstähle zu parametrisieren. Auf Grundlage der für Verpackungsstahl relevanten Umformprozesse wurde eine geeignete Validierungsprozedur abgeleitet, in der die verbesserte Güte der Simulation auf Basis der erstellten Materialdaten im Vergleich zum Stand der Technik gezeigt werden konn

Finite Elemente Simulation of Deep Drawing of Tailored Heat Treated Blanks - Geiger, Manfred; Merklein, Marion; Kerausch, Michael (Annals of the CIRP, 2004)
LFT Import::2019-08-05 (1055)

Flächige Leichtbauteile: Anwendungsmöglichkeiten im Automobilbau - Al-Sheyyab, Ahmad; Cojutti, Massimo; Kägeler, C.; Staud, Detlev; et al. (Konstruktion, 2008)
LFT Import::2019-07-29 (1506)

Flexibilisierung der Fertigung umformtechnisch erzeugter Bauteile durch prozessangepasste Halbzeuge - Merklein, Marion; Lechner, Michael (11. Umformtechnisches Kolloquium Darmstadt, 2012)
LFT Import::2019-08-05 (1802)

Flexible Formgebung von Blechen durch Laserstrahlumformen - Hennige, Thomas (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2001)
The main aim of this work was to develop a basic understanding of the mechanisms and parameters of the laser forming process to characterise the potentials of laser forming for rapid prototyping and small series production tasks. In order to analyse the geometrical constraints of the spatial forming process, the transition from linear laser bending to spatial laser forming was investigated using transition geometries with curved irradiation paths. These investigations showed the strong influence of the geometrical induced strain hindrances during the expansion phase and the contraction phase of the laser irradiation. Based on these results an analysis of suitable irradiation patterns and the resulting shaping potential of laser forming was possible. An iterative production sequence for the generation of a spherical bowl using basic irradiation sequences, adaptive irradiation sequences for correcting the local geometrical deviations and intermediate measurement cycles showed the feasibility of controlled flexible shaping by laser forming. In addition, the laser induced changes of the microstructure and the mechanical properties of the material were analysed in order to finally enable the definition of optimised irradiation strategies for laser forming of sheet metal part

Flexible Kinematic 3D-bending of Tubes and Profiles - Nock, Marco; Geiger, Manfred (Proceedings of the 7th International Conference on Technology of Plasticity, 2002)
LFT Import::2019-08-05 (1678)

Flexible Produktionsechnologien als Ziel - Technologien verzweifelt gesucht - Eßer, Gerd (Industrieanzeiger, 2000)
LFT Import::2019-07-15 (753)

Flexible prototyping of Sheet Metal Parts by Laser Forming - Hennige, Thomas (Proceedings International Conference on Competitive Manufacturing, 2001)
LFT Import::2019-07-15 (912)

Flexible Rolling of Process Adapted Semi-finished Parts and its Application in a Sheet-Bulk Metal Forming Process - Hildenbrand, Philipp; Schneider, Thomas; Merklein, Marion (Key Engineering Materials, 2015)
By applying bulk forming processes on sheet metals, thin-walled functional components with locally restricted wall thickness variations can be manufactured by forming operations. Using tailored blanks with a modified sheet thickness gradient instead of conventional blanks, an efficient controlling of the material flow can be achieved. One possible process to manufacture these semifinished parts is a flexible rolling process. Based on an established process strategy new results for steels of differing strength and work-hardening behavior are presented in this paper. The influences of each material on the resulting process forces and blank properties regarding the same target geometry are discussed. The tailored blanks are hereby analyzed by their geometrical dimensions, like sheet thickness, and their mechanical properties, e.g. hardness distribution. Additionally, the possibilities of processing these tailored blanks in a deep-drawing and upsetting process are presented with a hereby focus on the residual formability of the tailored blanks.
LFT Import::2019-07-29 (2069)
Keywords: Forming; Rolling; Sheet metal

Flexible rolling of rotational symmetric tailored blanks with a two-sided thickness profile - Vogel, Manfred; Merklein, Marion (Procedia Manufacturing, 2019)
The application of bulk forming operations to sheet metals leads to an increase of the material efficiency due to the enhancement of the process limits compared to conventional forming processes. The main challenges within the process class of sheet-bulk metal forming are high resulting forming forces and a defined control of the material flow. Additionally, the initial blank thickness influences the resulting quality of the geometrical and mechanical properties of functional components, like synchronizer rings. Previous investigations have shown that the application of tailored blanks with a defined one-sided thickness profile can meet these challenges which lead to an increase of the sufficient die filling of functional elements in subsequent forming processes. Due to the further increase of the geometrical complexity with functional elements in- and outside of the frame like carriers or gear teeth, the layout of the tailored blank has to be adapted. Thus, a two-sided thickness profile is necessary, for achieving the sufficient die filling of the functional elements. One possibility for manufacturing these semi-finished parts is a flexible rolling process which is used within the presented work. Thereby, it is necessary to develop a new process strategy for achieving a material thickening on both sides, rolled- as well as die-sided. For enabling a homogeneous material flow, the deep drawing mild steel DC04 with an initial sheet thickness of t0 = 3 mm is used, due to a high formability of this material. The tailored blanks are hereby analyzed regarding the resulting process forces, geometrical dimensions like the sheet thickness, mechanical properties such as the hardness distribution and the resulting surface roughness in important areas.
CRIS-Team Scopus Importer:2019-09-27
Keywords: Cold forming; Rolling; Sheet metal; Tailored blanks

Flexibles Biegen stranggepreßter Aluminium Profile - Geiger, Manfred; Arnet, Horst; Engel, Ulf; Vollertsen, Frank (Blech, Rohre, Profile, 1995)
LFT Import::2019-07-16 (1972)

Flexibles Biegen stranggepreßter Aluminium-Profile - Geiger, Manfred; Arnet, Horst; Engel, Ulf; Vollertsen, Frank (Blech, Rohre, Profile, 1995)
LFT Import::2019-07-15 (518)

Flexibles Biegen von Rohren und Profilen für die Innenhochdruckumformung - Nock, M.; Arnet, Horst (Idee-Vision-Innovation, Festschrift anläßlich des 60. Geburtstages von Professor Manfred Geiger, 2001)
LFT Import::2019-07-15 (830)

Flexible spatial forming of a tube using an elastomere tool - Nock, Marco; Geiger, Manfred (ICAFT 2003, 10. Sächsische Fachtagung Umformtechnik SFU, Proceedings of the 1st International Conference on Accuracy in Forming Technology, 2003)
LFT Import::2019-08-05 (1001)

Flexibles Profilbiegen mit Polyurethanmatrize - Geiger, Manfred; Engel, Ulf; Vollertsen, Frank; Arnet, Horst (Flexible Umformtechnik, 1995)
LFT Import::2019-08-05 (1983)

Flexible straightening of car body shells by laser forming - Geiger, Manfred; Vollertsen, Frank; Deinzer, Günter (Proceedings of the North American Deep Drawing Research Group (NADDRG), 1993)
Distortion after welding is one of the problems arising during the manufacturing especially of visible parts for car body shells. The straightening work has to be minimized in order minimize production times. A system is presented which may be used for cutting, welding and straightening of car body shell parts by application of a laser beam. Some aspects of distortion after laser beam welding are highlighted. Distortion decreases with increasing welding speed. The process of laser beam bending, e. g. bending with thermal induced stresses, is presented. It is shown that the process can be sufficientl controlled. Influence parameters on the working result are discussed. It is concluded that straightening by laser beam bending should be possible in an automated system. In addition, the results show that there are the same parameters which control the distortion after welding and the bending angle after laser beam bending. So the results from laser beam bending may be used to minimize the distortion after welding. © Copyright 1993 Society of Automotive Engineers, Inc.
LFT Import::2019-07-15 (415)

Fließkurvenermittlung für die Kaltmassivumformung druckaufgestickter Stähle - Merklein, Marion; Noneder, Johannes; Engel, Ulf (Proceedings Tagung Werkstoffprüfung, 2010)
LFT Import::2019-08-05 (746)

Fließpressen von Verzahnungselementen an Blechen - Pilz, Florian (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2020)
Forming technology is a promising production technique as it offers ecological and economic advantages due to short production times and high material efficiency. Cold forging in particular enables energy- and material-efficient production of highly loadable, precise steel components. Increasing demands on parts in terms of strength, weight and functional integration are pushing established forming processes for sheet metal and bulk forming to their limits. A combination of the process classes sheet and bulk forming combines their specific advantages, extends the limits of established forming processes and enables the production of geometrically complex components. Thus, weight-optimized (sheet metal) base bodies with local functionalization can be produced with minute functional elements such as gear teeth. In science and technology, this combination of processes is known as sheet-bulk metal forming. This work focuses on the production of sheet-bulk metal formed components by a forward and lateral extrusion process. Up to now, the achievable geometrical accuracy and the failure-critical tool load have been considered as major challenges and hinder an industrial application. With this in mind, this work aims at creating a fundamental process understanding for the extrusion of minute gearing elements using the example of running and locking gears on sheet metal. The process knowledge is the starting point for research into measures to extend current forming limit

Flow Behaviour of Advanced Aluminium Materials - Merklein, Marion; Biasutti, Manfredi; Hung Nguyen,; Böhm, Wolfgang (Steel research international: Special Edition: 10th International Conference on Technology of Plasticity, 2011)
The Accumulative Roll Bonding (ARB) process enables manufacturing lightweight sheet metals with outstanding mechanical properties. However, the significant increase In strength Is accompanied by a loss in ductility. The low formability obviously limits the Implementation of these sheet products for automotive applications but It may be enhanced by a local short term heat treatment according to the Tailored Heat Treated Blanks technology. The finite-element based design of the latter method needs accurate information about the plastic behaviour of these advanced materials. In this paper, the flow characteristics of the as-received and by accumulative roll bonding manufactured AA6016 sheets are investigated. Different stress - strain paths are considered testing both products using the tensile test and the layer compression test at room temperature with and without a previous heat treatment. The short term heat treatment Is realized to simulate the conditions occurring in the Tailored Heat Treated Blanks process. The experimental results are presented in form of true stress - strain curves and yield loci determined from different criteria and represented In a principal stress state. © 2011 Wiley-VCH Verlag GmbH & Co. KGaA. Weinheim.
LFT Import::2019-08-05 (1754)
Keywords: Accumulative roll bonding; Aluminium alloy; Material properties; Tailored heat treated blanks

Flow behaviour of magnetorheological fluids, considering the challenge of sealing in blank hydroforming in the flange area with rectangular leakage area cross-sections - Rösel, Sebastian; Merklein, Marion (Key Engineering Materials, 2011)
The need of light weight constructions and parts with tailored or even more homogeneous mechanical properties especially for structural components leads to the use of alternative forming technologies. These forming processes like sheet metal hydroforming are established to gain more flexibility and to increase the forming limits. But to apply this forming technology successfully, it is necessary to overcome some obstacles. One typical challenge for hydroforming of blanks, which has prevented further application of this technology, is the sealing of the cavity in the flange area. Nowadays there are a lot of basic approaches to accomplish a sealing in this tool area. Commonly a sealing can be reached by increasing the contact pressure in the outer region of the blank. This approach reduces the possible blank draw in and hence abates the possible realisation of complex part geometries. One possible approach to increase the ratio between cavity pressure and contact pressure in the flange area is the choice of a capable active fluid medium. The aim is to reduce the contact pressure in the flange area and nevertheless ensure a complete sealing. In this case the magnetorheological fluid (MR-fluid) BASF Basonetic 5030 is used as a pressure medium for hydroforming. For characterizing this fluid under different amounts of magnetic flux density and in comparison to a common hydraulic medium, an experimental setup was built up to gain process relevant data for hydroforming processes. Therefore different experiments were carried out with different media and different flux densities for the MR-fluid. To get more information about the mode of action and the accessible amounts of cavity pressure and related contact pressures in the flange area, these two process parameters were varied. © (2011) Trans Tech Publications.
LFT Import::2019-07-29 (1635)
Keywords: Active fluid media; Hydroforming; Magnetorheological fluid (MR-fluid); Sheet metal forming

Fluid elements in machine tools - Wegener, Konrad; Mayr, Josef; Merklein, Marion; Behrens, Bernd-Arno; Aoyama, Tojiro; Sulitka, Matej; Fleischer, Juergen; Groche, Peter; Kaftanoglu, Bilgin; Jochum, Nicolas; Moehring, Hans-Christian (CIRP Annals - Manufacturing Technology, 2017)
Fluids play a major role for production machinery and serve for very different tasks as lubricating, tempering, cleaning, transmitting force and energy. Due to maintenance requirements and the environmental impact their utilization is under discussion and alternatives are looked for. In this paper an overview of the latest research activities in the field of fluidic elements on machine tools is presented. The topic of the paper includes an overview of the fluids used in machine tools, the usage of fluidic elements, supply and treatment units, and their influence on machine tools performance. A link to fluidic media on energy efficiency is given. Research challenges in order to increase the performance of machine tools are discussed. The paper excludes metal working fluids, which have been treated in Brinksmeier et al. [33].
CRIS-Team Scopus Importer:2023-03-29
Keywords: Fluid; Machine tool; Performance

Formability Improvement with Tailored Heat Treated Blanks through an Inverse Simulation Approach - Staud, Detlev; Merklein, Marion (Proceedings of the 7th International Conference on Numerical Simulation of 3D Sheet Metal Forming Processes, 2008)
LFT Import::2019-08-05 (1557)

Formability of accumulative roll bonded aluminum AA1050 and AA6016 investigated using bulge tests - Topic, Irena; Höppel, Heinz Werner; Staud, Detlev; Merklein, Marion; Geiger, Manfred; Göken, Mathias (Advanced Engineering Materials, 2008)
The paper reports one of the very first attempts to investigate the formability of ultrafine- grained aluminum sheets produced by a severe plastic deformation process known as accumulative roll bonding. During hydraulic bulge testing the samples showed a tendency to higher achievable burst pressures and/or von Mises equivalent strains with increasing number of accumulative roll bonding cycles, indicating promising deformation behaviour and good formability.
WW1::765

Formability of Tailored Blanks from Steel and Aluminium Alloys. - Vollertsen, Frank; Schultz, Markus; Geiger, Manfred (Advanced Sheet Metal Forming, Proc. 19th Biennial IDDRG Congress (1996), 1996)
LFT Import::2019-08-05 (670)

Formability of the magnesium alloy AZ31 at elevated temperatures - Merklein, Marion; Beccari, S. (The 9th International Conference on Material Forming, ESAFORM 2006, Glasgow, United Kingdom, April 26-28, 2006)
LFT Import::2019-08-05 (1302)

Formability of ultrafine-grained AA6016 sheets processed by accumulative roll bonding - Hausöl, Tina; Schmidt, Christian; Maier, Verena; Böhm, Wolfgang; Nguyen, Manh Hung; Merklein, Marion; Höppel, Heinz Werner; Göken, Mathias (Key Engineering Materials, 2012)
Aluminium alloy AA6016 was accumulative roll bonded up to eight cycles in order to produce an ultrafine-grained microstructure. The formability of these sheets was investigated by means of bending tests. Furthermore the influence of a local laser heat treatment at the bending edge is observed. The strength of the UFG samples is increased by a factor of around two compared to the conventionally grained T4 condition which also results in up to 50 % higher punch forces needed for bending of ARB processed samples. An anisotropic bending behaviour is observed. By applying a tailored laser heat treatment along the bending edge prior to the bending tests a local recrystallization and recovery at the deformation zone of the samples is achieved. Thus, ductility is increased locally whereby bending to an angle of 80° is possible with lower forming forces compared to the non-heat treated specimens. The results are compared to previous studies on mechanical properties and formability investigations of ARB processed AA6016.
WW1::929

Forming characteristics of artificial aging Al-Mg-Si-Cu sheet alloys - Klos, Artur; Kellner, Sven; Wortberg, Daniel; Walter, Philipp; Bassi, Corrado; Merklein, Marion (AIP Conference Proceedings, 2017)
AA6111 is a commonly used aluminum alloy for body-in-white (BIW) components with good bake-hardening response, high strength and excellent formability. For industrial applications various process strategies are considered to reach strength of about 250 MPa in the final body part with that type of alloy. The purpose of this paper is to discuss recent process strategies of high-strength AA6111 sheets to evaluate the forming characteristics, precipitation kinetics dissolution and mechanical properties in the final condition. The forming behavior is investigated by four potential process chains after single-stage or multi-stage heat treatment including T4 (pre-aged at > 80 °C after quenching), T61 (T4 + artificial aged at 120-150 °C for 10-18 h), T6 (T4 + artificial aged at 180-220°C up to 12 h) and PFHT (T4 + post form heat treatment at 205°C for 30 min). The experimental input for characterization of the formability consists of tensile tests, bending tests and drawing tests. Differential Scanning Calorimetry (DSC) is used, to correlate the forming behavior with the precipitation distribution in the advanced stages of aging. The study shows that the forming behavior is strongly dependent on the condition the alloy.
CRIS-Team Scopus Importer:2023-03-29

Forming limits in sheet metal forming for non-proportional loading conditions? experimental and theoretical approach - Offenheimer, A.; Buchmayr, B.; Kolleck, R.; Merklein, Marion (Proceedings of the 6th International Conference and Workshop on Numerical Simulation of 3D Sheet forming Processes (NumiSheet), 15.-19.08., Detroit, USA, 2005)
The influence of strain paths (loading history) on material formability is well known in sheet forming processes. Sophisticated experimental methods are used to determine the entire shape of strain paths of forming limits for aluminum AA6016-T4 alloy. Forming limits for sheet metal in as-received condition as well as for different pre-deformation are presented. A theoretical approach based on Arrieux's intrinsic Forming Limit Stress Curve (FLSC) concept is employed to numerically predict the influence of loading history on forming severity. The detailed experimental strain paths are used in the theoretical study instead of any linear or bilinear simplified loading histories to demonstrate the predictive quality of forming limits in the state of stress. © 2005 American Institute of Physics.
LFT Import::2019-08-05 (1225)
Keywords: FLSC; Formability; Non-proportional loading; Pre-deformation; Strain path

Forming of complex functional elements on sheet metal - Reck, Manuel; Rohrmoser, Andreas; Jobst, Andreas; Pilz, Florian; Merklein, Marion (Sheet Bulk Metal Forming, 2021)

Forming of Components with Microgearings from Coil Material—Numerical Modeling of the Process Chain and Experimental Validation - Rohrmoser, Andreas; Kraus, Martin; Merklein, Marion (Micromachines, 2021)
Compared to alternative production methods, cold forming offers technological, economic and ecological potential for the mass production of microgears. Within the current boundaries of the technology, the cold forming of modules m < 0.2 mm is not possible due to size effects, high tool stresses and handling problems. The investigations of this contribution present a novel process chain for the multi-step forming of microgears with a module of m = 0.1 mm. For this purpose, a numerical model of the first two steps of the process chain is set up and confirmed based on experimental forming tests. The results have proven the feasibility of the process chain by a complete forming of the gear teeth.
Keywords: micro forming; microgear; sheet-bulk metal forming; multi-step micro forming

Forming of lightweight helical gears by means of sheet-bulk metal forming - Reck, Manuel; Merklein, Marion (2024)

Forming of metal-based composite parts - Bruschi, S.; Cao, J.; Merklein, Marion; Yanagimoto, J. (CIRP Annals - Manufacturing Technology, 2021)
In the last few decades, metal-based composites and related manufacturing methods have attained a significant research attention thanks to the possibilities they offer to tailor both the material properties and the part in-service performances. A variety of metal-based composite parts is available for commercial applications since more affordable and robust manufacturing processes and quality control techniques have recently overcome many challenging technological issues. The paper aims at describing the forming processes applied to metal-based composites, with particular emphasis on the process features, part obtainable characteristics, and modelling issues for a convincing design and optimization of the process itself. The most recent progresses and challenges are illustrated in detail, including innovative materials and processes that are emerging to answer the requirements of advanced engineering applications as well as new modelling techniques and current approaches to face economic and environmental issues.
CRIS-Team Scopus Importer:2021-07-30
Keywords: Composite; Forming; Metal

Forming Process Parameter Dependent Recrystallization Phenomena in Friction Stir Welded Aluminium Sheets - Gnibl, Tobias; Merklein, Marion (7th International Conference and Exhibition on Design and Production of Machines and Dies/Mold, 2013)
LFT Import::2019-08-05 (2033)

Formklassifizierung von Blechteilen mit Fuzzy-Logic - Geiger, Manfred; Backes, Frank; Greska, Wolfgang (CIM-Management, 1993)
LFT Import::2019-07-15 (386)

Fortschritte in der Fügetechnik für Aluminium - Schmidt, Michael; Mys, I.; Albert, F.; Merklein, Marion; Giera, Artur; Staud, Detlev (Proceedings Euroform-Konferenz, Aluminium, Anwendungen, Märkte, Produktion, 2006)
LFT Import::2019-08-05 (1317)

Fortschrittliche Programmierung von 3D-Laseranlagen. - Geiger, Manfred; Reinhart, G.; Backes, Frank; Bauer, L. (Blech, Rohre, Profile, 1996)
LFT Import::2019-07-15 (654)

Forward and Reverse Simple Shear Test Experiments for Material Modeling in Forming Simulations - Merklein, Marion; Biasutti, Manfredi (Proc. of the 10th International Conference on Technology of Plasticity (ICTP), 2011)
The planar simple shear test has become of Increasing Interest for the material parameter Identification as well as validation of material models In sheet metal forming simulations. In this paper, a modified shear specimen geometry based on the ASTM standard B831, optimized for performing monotone and reverse simple shear test, Is presented. Experiments are carried out under monotone loading for an aluminum sheet alloy AA6016 and found in good agreement with previous results obtained from a Mlyauchi based simple shear test. Following this verification Bauschinger simple shear tests conducted with reversal of shear after different amounts of forward prestrain are performed and compared by means of applying an anisotropic yield function with the more standard tension-compression test. In conclusion, a further development of the simple shear setup is presented for characterizing sheet metals at elevated temperatures by means of electric conductive warming of the modified shear sample. © 2011 Wiley-VCH Verlag GmbH & Co. KGaA. Weinheim.
LFT Import::2019-08-05 (1762)
Keywords: Bauschinger effect; Material characterization; Simple shear test

Friction Characterisation for a Tumbling Self-Piercing Riveting Process - Wituschek, Simon; Lechner, Michael (Key Engineering Materials, 2021)
Due to increasing demands regarding ecological and economic specifications in vehicle design, the effort required for production is continuously increasing. One trend is the increased use of multi-material systems, which are characterised by the use of different materials such as high-strength steels or aluminium alloys. In addition to the varying mechanical properties of the components, an increased number of variants accompanied by different geometries is leading to increasing challenges on body construction. For the assembly and connection of the individual components, conventional joining methods reach their limitations. Therefore, new joining methods are necessary, which feature properties of versatility and can adapt to process and disturbance variables. One way of achieving tailored joints is to use a tumbling self-piercing riveting process. For the design of the process route, numerical investigations are necessary for which a characterisation of the friction properties is necessary. This paper therefore investigates the contact and friction conditions that occur in a tumbling self-piercing riveting process. The individual contacts between the process components are identified and based on this, suitable processes for the characterisation of the friction factors - and coefficients are selected and performed.
Keywords: Friction; Joining; Self-Piercing riveting

Friction Conditions in Sheet-Bulk Metal Forming - Vierzigmann, Ulrich; Merklein, Marion; Engel, Ulf (Procedia Engineering, 2011)
LFT Import::2019-08-07 (1753)

Friction reduction in EHL contacts by surface microtexturing – tribological performance, manufacturing and tailored design - Tremmel, Stephan; Marian, Max; Zahner, Michael; Wartzack, Sandro; Merklein, Marion (Industrial Lubrication and Tribology, 2019)
Purpose – This paper aims to derive tailor-made microtextures for elastohydrodynamically lubricated (EHL) contacts under consideration of manufacturing possibilities. Design/methodology/approach – Component tests were used for the evaluation of the influence of surface texturing on the friction behavior in the cam/tappet contact. Furthermore, the manufacturing possibilities and limitations of a combined mEDM and micro coining process and the feasibility of integration into a forming process were studied. Finally, a methodology based on transient EHL simulations and a meta-model of optimal prognosis was exemplarily used for microtexture optimization. Findings – It was found that surface texturing in EHL contacts with high amount of sliding is promising. Moreover, the combination of mEDM and micro coining and the integration into established production processes allow the manufacturing of microtextures with desirable structural parameters and sufficient accuracy. Originality/value – This paper gives a holistic view on surface microtexturing over several phases of the product life cycle, from the design, over efficient manufacturing to application-related testin
Keywords: Friction; Elastohydrodynamic lubrication; Micro coining

Friction stir knead welding of steel aluminium butt joints - Geiger, Manfred; Micari, F.; Merklein, Marion; Fratini, Livan; Contorno, D.; Giera, Artur; Staud, Detlev (International Journal of Machine Tools and Manufacture, 2008)
To develop steel aluminium-tailored hybrids in a butt joint for sheets in a thickness of about 1 mm conventional Friction Stir Welding is not feasible due to a high distortion of the welded specimen. Contrary to Friction Stir Welding the tool used for Friction Stir Knead Welding has no pin wherefore higher welding speeds can be realised. Due to the fact that this is a newer process, applied for patent in 2005, the cut contours of the edges and their variations have to be optimised by numerical analysis to transfer a maximum of load in order to improve the formability. The examined materials in this paper are steel DC04, as well as the aluminium alloys AA5182 and AA6016 in sheet thicknesses of 1 mm. Accompanying experimental investigations, as tensile tests, will evaluate the quality of the welding mechanism. As the mechanics of the new welding technology is not fundamentally investigated until now, metallographic investigations are performed, and additionally micro hardness measurements are carried out to verify the changes in the hardness distribution in the welding zone after stirring and welding. © 2007 Elsevier Ltd. All rights reserved.
LFT Import::2019-07-29 (1509)
Keywords: Aluminium; Friction Stir Knead Welding; Simulation; Steel

Friction stir welding and cup deep drawing of aluminium tailored blanks - Merklein, Marion; Giera, Artur; Staud, Detlev (Proceedings of the 8th ESAFORM Conference on material forming, 2005)
LFT Import::2019-08-05 (1162)

Friction stir welding of aluminium foam sandwich - Geiger, Manfred; Dörfler, Stephan Manuel; Otto, Andreas (Production Engineering Research and Development - Annals of the German Academic Society for Production Engineering, 2005)
LFT Import::2019-08-05 (1123)

Friction stir welding of aluminium foam sandwich precursor material - Dörfler, Stephan Manuel; Otto, Andreas (Advanced metallic materials and their joinig, 25.-27.10.2004, Bratislava, Slovakei, 2004)
LFT Import::2019-08-05 (1079)

Friction Stir Welding of Light Weight Sandwich Materials - Dörfler, Stephan Manuel; Otto, Andreas (Sheet Metal 2005, Proceedings of the 11th International Conference on Sheet Metal; Advanced Materials Research, 2005)
Ever since its invention, friction stir welding has been of great interest for the joining of light weight materials. Due to joining in the solid state, friction stir welding inheres characteristic advantages that are unmatched by conventional fusion welding techniques. At the Chair of Manufacturing Technology friction stir welding is employed to develop a process chain for the production of highly load adapted car body components out of aluminum sheet metal and aluminum foam sandwich (AFS) by tailored blanking. In contrast to friction stir welding other materials, special measures have to be taken, since AFS comprises a layered material structure out of two solid aluminum sheet metal cover layers and a powder metallurgically produced core layer. After welding, the tailored blank is subjected to forming, foaming and a final laser cutting process. High temperature capability of the weld seam must be assured, hence foaming of the powder metallurgic core layer requires temperatures of up to 95% of core layer-solidus temperature. Therefore not only mechanical properties are revealed, but also temperature capability is assessed by differential scanning calorimetry (DSC). Additionally the weld seams are tested during foaming by the use of special specimen geometry. Due to the high deformation and temperature while welding and foaming, the metallurgical structure at the weld seam undergoes some modifications, which are subject to metallographic analysis and hardness testing. As an outlook, new material developments towards 6000 aluminum alloys as cover sheet materials will be discussed with regard to the process chain.
LFT Import::2019-08-05 (1204)
Keywords: Aluminum foam sandwich; Friction; Welding

Friction stir welding of thin steel aluminium hybrid blanks - Merklein, Marion; Giera, Artur (The 9th International Conference on Material Forming, ESAFORM 2006, 2006)
LFT Import::2019-08-05 (1306)

Friction Stir Welds Made Out of Precipitation Hardenable Aluminum Alloys - Experimental Investigations of Formability Potential - Merklein, Marion; Wieland, Michael; Staud, Detlev (International Journal of Material Forming, 2009)
The industrial application of aluminum alloys in lightweight constructions is basically connected to two fundamental manufacturing requirements. First, the formability of aluminum blanks must be adequate in order to shape the required geometries. This requirement can be fulfilled by using precipitation hardenable aluminum alloys which can be formed well in natural aged condition. In common, these alloys are artificially aged afterwards for getting a higher strength. Second, suitable joining technologies must be available for connecting the formed elements to a complex lightweight construction. One such joining technology could be friction stir welding (FSW), because of better mechanical properties due to lower heat input compared to other joining technologies, for example laser welding. Thereby also Tailored Welded Blanks (TWB), which are used for reducing the number of parts or for locally reinforcing structures, can be used for aluminum lightweight constructions. Beside these attributes dominated by production technology weld seams must also fulfill utilization based requirements. One such criterion is that a misapplication of aluminum lightweight constructions, which are commonly used in transportation systems, is not leading to a complete failure. Therefore aluminum joints, which are connecting the formed parts, should have certain formability to balance a local overstraining. For the implementation of this consideration the formability of FSW joints made out of AA6016 aluminum is investigated in this paper. Therefore local martens hardness distribution of unformed, formed and artificially aged welds are conducted and the results are compared to each other. © Springer/ESAFORM 2009.
LFT Import::2019-07-29 (309)
Keywords: Aluminum; Deep drawing; Friction stir welding

Fringe projection profilometry in production metrology: A multi-scale comparison in sheet-bulk metal forming - Hinz, Lennart; Metzner, Sebastian; Müller, Philipp; Schulte, Robert Karl; Besserer, Hans-Bernward; Wackenrohr, Steffen; Sauer, Christopher; Kästner, Markus; Hausotte, Tino; Hübner, Sven; Nuernberger, Florian; Schleich, Benjamin; et al. (Sensors, 2021)
Fringe projection profilometry in combination with other optical measuring technologies has established itself over the last decades as an essential complement to conventional, tactile measuring devices. The non-contact, holistic reconstruction of complex geometries within fractions of a second in conjunction with the lightweight and transportable sensor design open up many fields of application in production metrology. Furthermore, triangulation-based measuring principles feature good scalability, which has led to 3D scanners for various scale ranges. Innovative and modern production processes, such as sheet-bulk metal forming, thus, utilize fringe projection profilometry in many respects to monitor the process, quantify possible wear and improve production technology. Therefore, it is essential to identify the appropriate 3D scanner for each application and to properly evaluate the acquired data. Through precise knowledge of the measurement volume and the relative uncertainty with respect to the specimen and scanner position, adapted measurement strategies and integrated production concepts can be realized. Although there are extensive industrial standards and guidelines for the quantification of sensor performance, evaluation and tolerancing is mainly global and can, therefore, neither provide assistance in the correct, application-specific positioning and alignment of the sensor nor reflect the local characteristics within the measuring volume. Therefore, this article compares fringe projection systems across various scale ranges by positioning and scanning a calibrated sphere in a high resolution grid.
CRIS-Team Scopus Importer:2021-04-09
Keywords: Coordinate metrology; Fringe projection; Production metrology; Sheet-bulk metal forming

From Research to Practical Applications - Rapid Prototyping at the BLZ - Coremans, Arjan; Dierken, R.; Hoffmann, Peter (Proceedings of the 7th European Conference on Rapid Prototyping and Manufacturing, Aachen, 1998)
LFT Import::2019-08-05 (1369)

From Research to Practical Applications - Rapid Prototyping in the Future - Coremans, Arjan; Dierken, R.; Hoffmann, Peter (Proceedings of the ICALEO Europe 98, 1998)
LFT Import::2019-08-05 (1368)

Fügen durch Umformen - Das Spannungsfeld zwischen Umform- und Fügetechnik - Merklein, Marion; Grüner, Martin; Müller, Martin; Wieland, Michael (Effiziente Fertigung von Hochleistungsverbundsystemen - Proc. 18. Paderborner Symposium Fügetechnik, 2013)
LFT Import::2019-08-05 (2009)

Fügen von niedriglegiertem Baustahl im Dünnblechbereich durch flußmittelfreies Laserstrahlhartlöten. - Hanebuth, Henning; Geiger, Manfred (Proc. der Deutsch-Französischen Tagung Mechanik und Optik - Hochleistungslaser im Maschinenbau, 1995)
LFT Import::2019-08-05 (560)

Fügen von Schaum - Otto, Andreas; Klausecker, Roland; Hahn, Markus (Metallschäume? Herstellung, Eigenschaften und Anwendungen. DGM-Fortbildungsseminar, 2002)
LFT Import::2019-08-05 (1717)

Fully Automated Nd:YAG-Welding-System for Assembly of Electronic Components - Geiger, Manfred; Breitenbach, Frank; Govekar, E.; Brassel, Jan-Oliver (Proceedings of the ICARCV 1998, 1998)
LFT Import::2019-08-05 (1585)

Fully Automated Quality Assurance Tools for Laser Beam Joining of SMT Devices - Brassel, Jan-Oliver; Breitenbach, Frank; Schmidt, Michael (Proceedings of the 3rd International Congress on Molded Interconnected Devices MID 1998, 1998)
LFT Import::2019-08-05 (1365)

Functional Analysis of Components Manufactured by a Sheet-Bulk Metal Forming Process - Hetzel, Andreas; Schulte, Robert Karl; Vogel, Manfred; Lechner, Michael; Besserer, Hans-Bernward; Maier, Hans Juergen; Sauer, Christopher; Schleich, Benjamin; Wartzack, Sandro; Merklein, Marion (Journal of Manufacturing and Materials Processing, 2021)
Due to rising demands regarding the functionality and load-bearing capacity of functional components such as synchronizer rings in gear systems, conventional forming operations are reaching their limits with respect to formability and efficiency. One way to meet these challenges is the application of the innovative process class of sheet-bulk metal forming (SBMF). By applying bulk forming operations to sheet metal, the advantages of both process classes can be combined, thus realizing an optimized part weight and an adapted load-bearing capacity. Different approaches to manufacturing relevant part geometries were presented and evaluated regarding the process properties and applicability. In this contribution, a self-learning engineering workbench was used to provide geometry-based data regarding a novel component geometry with circumferential involute gearing manufactured in an SBMF process combination of deep drawing and upsetting. Within the comprehensive investigations, the mechanical and geometrical properties of the part were analyzed. Moreover, the manufactured components were compared regarding the increased fatigue strength in cyclic load tests. With the gained experimental and numerical data, the workbench was used for the first time to generate the desired component as a CAD model, as well as to derive design guidelines referring to the investigated properties and fatigue behavior.<br
Keywords: sheet-bulk metal forming; mechanical properties; self-learning engineering workbench; functional behavior; fatigue life modeling; Z-integral approach

Functional Integration of Sheet Metal Parts by Deep Drawing - Merklein, Marion; Schneider, Thomas (Steel Research International, 2011)
A novel deep drawing process for manufacturing rotationally symmetric components with shape elements In the cup wall Is presented. Aim of this Investigation Is the Integration of functional elements at deep drawn workpleces In a single forming stage to meet the trend towards high Integration density at short process chains. The challenge of this process Is the realization of minimum fillets In relation to the sheet thickness as miniaturization and integration density are major targets in the development of functional components. The results show, that the filigree design of the shape elements can cause sharp bending of the blank and thus non-uniform draw-in as well as inhomogeneous strain-hardening. Furthermore, the geometry of the component and the corresponding die and punch design lead to non-uniform application of the forming force, which particularly acts at the shape elements and results in local sheet thinning. In combination with the specific draw- in, this results in locally varying contact conditions. High contact normal stresses occur at the minimum fillets whereas curvature of the blank during draw-in Inhibits even local contact between workplece and drawing die. In addition, the effects of deep drawing a cup with integrated shape elements are discussed and appropriate modifications of the process are shown to improve accuracy of shape. © 2011 Wiley-VCH Verlag GmbH & Co. KGaA. Weinheim.
LFT Import::2019-07-29 (1726)
Keywords: Functional integration; Sheet drawing; Tools and dies

Functional optimization of hot-stamped components by local carburization - Horn, Alexander; Merklein, Marion (International Journal of Lightweight Materials and Manufacture, 2020)
One of the major challenges in modern car body construction is the reduction of component weight while still maintaining passenger safety. In terms of these requirements, the substitution of conventional steel grades by ultra-high strength materials is the most promising approach. Hot stamping of these steels has developed to a state of the art process for manufacturing safety-relevant car body parts such as B-pillars or front bumpers. By locally adjusting the mechanical properties, for example, increasing the ductility, passive safety can be further improved. For this purpose, the hot stamping process is adapted in different ways. Varying from these established methods, tailored carburization is an alternative approach for manufacturing functional optimized components by combining hot stamping with prior local carburization. Within this work, the potential of local carburization is analyzed by a fundamental investigation of the influence of the process parameters on the mechanical properties as well as the transition zones between carburized and non-carburized areas. Besides the mechanical properties, the heat transfer between carburized sheets and tools is studied. The process suitability is validated by a demonstrator.
CRIS-Team Scopus Importer:2020-05-22

Functional protective coatings for improved tool life in cold forging - Engel, Ulf; Hinsel, Christian; Geiger, Manfred (THE Coatings, Proc. of the 1st Int. Conf., 14-15 Oct 1999 Thessaloniki, Greece, 1999)
None
LFT Import::2019-08-05 (2001)

Fundamental analysis For the application of hybrid semi-finished products in sheet-bulk metal forming - Schulte, Robert Karl; Lechner, Michael; Merklein, Marion (Journal of Materials Processing Technology, 2020)
Sheet-bulk metal forming is an expedient approach to efficiently manufacture functional components out of sheet metal. In order to reduce weight of the component manufactured, an application-adapted approach was developed to replace the conventional steel blank by a semi-finished product consisting of two blanks with half the thickness to enable the tailored combination of different materials in a combined deep drawing and upsetting process. To establish a basis for the application of these hybrid semi-finished products, first of all multilayer steel semi-finished products are drawn and upset in the process combination. Thereby, the upsetting process induces a three dimensional material flow and at the same time an interlocking connection of the two blanks. The gained results are the transferred onto the combination of steel and aluminium alloys within one semi-finished product. Fundamental dependencies as well as the influence of the application of different steel grades are investigated.
CRIS-Team Scopus Importer:2020-04-28
Keywords: Metal forming; Sheet metal; Simulation

Fundamental aspects for the evaluation of the fatigue behavi¬our of cold forging tools - Falk, Bernd; Engel, Ulf; Geiger, Manfred (Journal of Materials Processing Technology, 1999)
LFT Import::2019-07-16 (2003)

Fundamental investigations concerning forming limit diagrams - Merklein, Marion (Advanced Technology of Plasticity, Proceedings of the 7th ICTP, 2002)
LFT Import::2019-08-05 (1718)

Fundamental Investigations on Friction Stir Knead Welding - Contorno, D.; Fonti, V.; Giera, Artur; Fratini, L.; Merklein, Marion (2nd International Conference on New Forming Technology, 2007)
LFT Import::2019-08-05 (1452)

Fundamental investigations on the material flow at combined sheet and bulk metal forming processes - Merklein, Marion; Koch, Johannes Peter Karl; Opel, Simon; Schneider, Thomas (CIRP Annals - Manufacturing Technology, 2011)
The class of combined sheet and bulk metal forming (SBMF) processes denotes the forming of sheet metals with typical bulk forming operations. As a consequence, simultaneous 2D and 3D stress and strain states are present. Furthermore the local shape elements formed out of the sheet plane are in the magnitude of the sheet thickness. This paper deals with process combinations upsetting/lateral extrusion and deep drawing/upsetting. It has been shown that an insufficient mould filling is nearly inevitable using conventional tooling systems. Hence, the prospect of newly developed forming approaches will be discussed. © 2011 CIRP.
LFT Import::2019-07-29 (1633)
Keywords: Forming; Processing; Simulation

Fundamental Investigations to Evaluate the Influence of Notching Processes on a Subsequent Cyclic Bending Process for the Production of Wire Cores - Biallas, Alina; Ohmayer, Sophia; Merklein, Marion (Journal of Manufacturing and Materials Processing, 2023)
The production of wire cores by notch rolling and cyclic bending promises an ecologically and economically efficient manufacturing option for steel fibers. The paper at hand evaluates the influence of wire strips on cyclic bending by applying rolled wire strips of DP600 sheet metal (t0 = 0.8 mm) and a new cyclic bending testing tool. Analysis of material separation with varying parameters, rolling gap d and bending angle β, proves the interdependency of both process step, but indicates reduced adjustability of the notch rolling process. To enable better adjustability of the wire strip’s characteristics and analysis of their effects, wire strip production in the laboratory by notch stamping instead of rolling is aspired. The prior interaction analysis states the web height b, the notch angle α, and the hardening distribution as relevant wire strip’s characteristics to be replicated. Based on experimental analysis, an equivalent of notch rolling by notch stamping is deduced by considering the web height b identical for stamping and rolling, by adjusting the tool’s notch angle αt based on an equation considering geometric evaluations of α, and by taking advantage of the asymmetric hardening distribution of the outer notch which is comparable to rolled wire stri
Keywords: stamping; rolling; wire strip

Fundamental mechanisms and their interactions in shear‐clinching technology and investigation of the process robustness - Wiesenmayer, Sebastian; Han, D.; Müller, Manuel; Hoerhold, R.; Meschut, G.; Merklein, Marion (Materialwissenschaft und Werkstofftechnik, 2019)
The compliance with increasingly stricter emission standards is a challenge for the automotive industry, which requires the utilization of lightweight materials e. g. aluminium and high-strength steels. Hereby, the load-optimized design of body parts and the reduction of wall thicknesses are enabled. But, due to the use of dissimilar materials, common joining technologies are reaching their limits. On the one hand, joining by welding is often not possible because of different melting temperatures. On the other hand, joining by forming with additional fasteners increases the cycle time and the costs. However, joining by forming without fasteners is often limited by the mechanical properties of the joining partners. The innovative shear-clinching technology combines shear-cutting and clinching in a single stage process and thereby enables joining by forming of materials with high differences regarding their mechanical properties. However, by the combination of the sub-processes cutting and joining, the complexity of the technology is increased. Thus, within the scope of this work, the fundamental mechanisms in shear-clinching and their interactions as well as the robustness of the process are analysed, in order to promote the applicability of the technology.
CRIS-Team WoS Importer:2019-08-09

Fundamentals on the manufacturing of sheet metal micro parts. - Geiger, Manfred; Vollertsen, Frank; Kals, Roland (CIRP Annals - Manufacturing Technology, 1996)
LFT Import::2019-07-15 (658)

Fundamental Studies on a Novel Die Concept for Round-Point Shear-Clinching - Hoerhold, Rejane; Müller, Martin; Merklein, Marion; Meschut, Gerson (AIP Conference Proceedings, 2016)
LFT Import::2019-07-29 (2190)

Funktionale 3D-Oberflächenkenngrößen in der Umformtechnik - Pfestorf, Markus (Friedrich-Alexander-Universität Erlangen-Nürnberg, 1997)
For the tribological characterization of the topography the common two dimensional surface parameters like Ra or Rz are not very suitable. Thus, the development of new three dimenional surface parameters is essential. The basic parameters, which can be derived from a mechanical-rheological model, are the material area ratio as well as the open and closed void area ratio. The most important parameters are the maximum of the closed void area ratio a clm as well as the closed void volume. Aiming a reliable determination of the surface paramters, a measurement guideline was developed. It is also shown that the influence of the size of the evaluation area as well as the form divergence can be observed. The results from several tribological tests show that there is a correlation between the surface parameters and the tribological properties of the topography. The capability of the surface parameters in industrial application is shown in two different examples. The first one is the use in temper mill rolling. The wear of the rolls in 61 km was shown by the three dimensional surface parameters of cold rolled steel strip. In a press shop, studies were made how to use the surface parameters for the quality control of the steel shee

Funktionsintegration durch die Kombination additiver Fertigungsprozesse mit der Blechumformung - Schaub, Adam; Merklein, Marion; Jüchter, Vera; Singer, Robert; Körner, Carolin (2. Industriekolloquium des Sonderforschungsbereichs 814 - Additive Fertigung, 2013)
None
LFT Import::2019-08-05 (1930)

Funktionsprototypen aus PEEK - Rechtenwald, T.; Roth, Stephan; Pohle, D. (Kunststoffe, 2006)
LFT Import::2019-07-16 (1288)

Future Challenges in Precision Forging Technology? A Report of Discussion Hour at the 4th ISPF - Kitamura, K.; Matsumoto, R.; Putz, Alexander (Proceedings of the 39th Plenary Meeting of the International Cold Forging Group (ICFG), Changwon, Korea, 2006)
LFT Import::2019-08-05 (1307)

Ganzheitliche Erarbeitung eines Prozessverständnisses von Tiefziehprozessen mit Ziehsicken auf Basis mechanischer und tribologischer Analysen - Schmid, Harald (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2022)
In the correlation of saving resources and the reduction of CO2 emissions, lightweight construction plays a key role in the mobility sector. To face that, correctives such as lightweight material construction or form lightweight construction are used. For the production of car body components without failure or defects in deep drawing, drawbeads among other things are used. These are cylinder-like indentations in the flange area to control the material flow, whereas there is a lack of a broad understanding of the effect of a drawbead on the mechanical and tribological system. Subsequently, the overall objective of the work was to work out an integrally understanding of the process and to evaluate and increase the prediction ac-curacy for deep drawing processes with drawbeads for three different materials. Therefore, systematically derived methodical steps were used in two stages on the basis of the model test “strip drawing with drawbeads” and a deep drawing setup with drawbeads. The work is focused on the qualification of suitable measurement methods, such as an optical in-situ strain measurement, in order to carry out a multilevel process analysis and to de-rive correlations. Furthermore, the simulation accuracy was evaluated on the basis of experimental measurements and the quality of the prediction was improved by transferring the findings. Within the scope of a validation on deep-drawn components, the findings could be transferred and also additionally differentiated for linear and convex drawbeads. The work concludes with a summary and an outlook on relevant topics in the futur

Genaubearbeitung beim Schneiden von Stahlblechen mit CO2- Lasern - Nuss, Rudolf; Biermann, S; Geiger, Manfred (Blech, Rohre, Profile, 1987)
LFT Import::2019-07-15 (190)

Genaubearbeitung von Feinblechen durch Laserstrahlschneiden - Geiger, Manfred; Nuss, Rudolf (Laser-Materialbearbeitung für den Automobilbau, 1987)
LFT Import::2019-07-15 (187)

General overview of research activities in cold forging at the LFT - Falk, Bernd; Popp, Uwe (Proceedings of the 2nd JSTP International Seminar on Precision Forging, 2000)
LFT Import::2019-08-05 (758)

Generation of ceramic coatings by laser pyrolysis of organo-metallic polymers - Geiger, Manfred; Ziegler, G.; Engel, Ulf; Motz, G.; Krauß, Hans-Joachim (THE Coatings, Proc. of the 1st Int. Conf., 14-15 Oct 1999 Thessaloniki, Greece, 1999)
None
LFT Import::2019-08-05 (2002)

Generation of Functional Coatings and Structures by Laser Pyrolysis of Preceramic Polymers - Geiger, Manfred; Krauß, Hans-Joachim (Production Engineering. Annals of the German Academic Society for Production Engineering, 2006)
LFT Import::2019-08-05 (1342)

Generation of functional structures by laser pyrolysis of polysilazane - Krauß, Hans-Joachim; Otto, Andreas (LASE 2002 Conference on High-Power Lasers and Application, 2002)
LFT Import::2019-08-05 (1702)
Keywords: Additive structuring; Functional structures; Laser pyrolysis; Polysilazane; Surface treatment

Geometrical Feature Based Closed Loop Control System for the Correction of Warpage - Hutterer, Angelika; Otto, Andreas (Proceedings of the Fifteenth International Conference on Systems Engineering(ICSE), 2002)
LFT Import::2019-08-05 (1700)

Geometrical variations of tubes and their impact on freeform bending processes - Vatter, Peter; Plettke, Raoul (Advanced Materials Research, 2013)
In bending processes for tubes and profiles, the produced bending geometry depends on the characteristics of the semifinished product. Tubes are subjected to scatter and deviations from the standard's dimensions caused by their fabrication process. This results in deviations of the forming behaviour. Depending on the bending process, the effect of this phenomenon is even larger, if the deviation of process forces leads to a significant deflection of the die elements. Particularly kinematic bending processes, e. g. the 3-roll-push-bending process have shown to be highly sensitive to low machine stiffness. The effect of this factor has not been identified among the influences of other disturbance factors so far. As an additional aspect, the tube dimensions affect the material characterization which leads to inaccurate material properties in numerical simulations. This results in wrong input data for the process design and has to be corrected in lengthy adjustment procedures. In this contribution the scatter of some geometrical tubes properties and its impact on the 3-rollpush- bending process is investigated. The tube geometry is measured by a tactile measurement system and is compared to the product standards. Observed deviations are categorized according to DIN 4760. The impact of the deviations on the bending process is examined by numerical variant calculations. Besides the tube dimensions, the stiffness of the machine is varied and the influence determined. By considering the errors resulting from wrong input data in the material characterization the overall error is quantified. © (2013) Trans Tech Publications, Switzerland.
LFT Import::2019-07-29 (1885)
Keywords: Batch variations; Bending; Finite element method (FEM)

Geometric and corrosive influences on load-bearing capacity of multi-element shear-clinching specimen - Han, Daxin; Wiesenmayer, Sebastian; Merklein, Marion; Meschut, Gerson (AIP Conference Proceedings, 2019)
The influences in the experimental investigation are divided into the geometry of the specimen and the corrosion phenomenon. The 8-element specimens were joined with various overlaps in the form of a single lap shear load multi-element specimen. Afterwards, the multi-element specimens were segmented into one-element specimens, which were tested under quasistatic shear load in order to detect possible influences of the specimen geometry. The effect of corrosion on the load-bearing capacity was investigated with the same multi-element specimen according to VDA 621-415. In addition, two arrangements of corrosion protection were generated in order to guarantee the joint quality in a corrosive surrounding atmosphere. It was found that the load-bearing capacity of specimens as well as the joint characteristics can be ensured using corrosion protection. The study gave a recommendation for planning the shear-clinching on a flange facing and showed promising potential for shear-clinching when joining multi-element specimens.
CRIS-Team Scopus Importer:2019-07-23

Geometric and mechanical joint characterization of conventionally and tumbled self-piercing riveting joints - Wituschek, Simon; Kappe, Fabian; Meschut, Gerson; Lechner, Michael (Proceedings of the Institution of Mechanical Engineers Part L-Journal of Materials-Design and Applications, 2022)
In view of economic and ecological trends, the concepts for lightweight construction in transport systems are becoming increasingly important. These are frequently applied in the form of multi-material systems, which are characterized by the selective use of materials and geometries. One major challenge in the manufacturing of multi-material systems is the joining of the individual components to form a complete system. Mechanical joining processes such as semi-tubular self-piercing riveting are frequently used for this application but reach their limits concerning the number of combinations of geometry and material. In order to react to the requirements and to increase the versatility of semi-tubular self-pierce riveting, a process combination consisting of a tumbling process and a self-pierce riveting process has been presented previously. This process combination is used in this work to investigate the versatility and to identify the influencing parameters on it. For this purpose, experiments are conducted to identify process-side influence possibilities. The tests are performed with a dual-phase steel aluminum alloy to represent the varying mechanical characteristics of multi-material systems. Furthermore, the initial sheet thicknesses of the joining partners are varied in several steps. In addition to the geometric joint formation used to describe the undercut, the rivet head end position and the residual sheet thickness, the joining process, is also analyzed during the investigations. Further, the innovative joining process is evaluated by comparing it with a conventional self-piercing riveting process. The knowledge obtained represents a basis for the identification and evaluation of the versatility of the process combination.<br

Geometrieeinflüsse beim Laserstrahlschneiden - Biermann, Stefan; Geiger, Manfred; Hoffmann, Martin; Nuss, Rudolf (Proc. 2nd European Conf. Laser Treatment of Materials (ECLAT 88), Bad Nauheim, 1988)
LFT Import::2019-08-05 (256)

Gezielte Beeinflussung der einsatzrelevanten Bauteileigenschaften kaltfließgepresster Zahnräder - Rohrmoser, Andreas; Kiener, Christoph; Schubert, Dirk W.; Hagenah, Hinnerk; Drummer, Dietmar; Merklein, Marion (Konstruktion, 2019)
LFT Import::2019-07-29 (2385)

Größeneffekte bei Biegeprozessen- Entwicklung einer Methodik zur Identifikation und Quantifizierung - Diehl, Alexander (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2010)
Based on an exemplary bending process a methodology enabling the identification and quantification of the influence of size effects on forming processes exhibiting strain gradients is presented and current deficits of conventional FE-simulation of the bending process are pointed out. Applying this methodology, approaches aiming for an improved description of the bending process are derived with the emphases being on the qualification of advanced methods for material characterisation, e.g. hydraulic and pneumatic bulge test and the implementation of strain gradient dependent material behaviour in the analytical and simulation based description of the forming proces

Grundlagen und Anwendungsgebiete von Ultrakurzpulslasern - eine übersicht - Dirscherl, Manfred; Schmidt, Michael (Laser in der Elektronikproduktion & Feinwerktechnik; Tagungsband des 8. Erlanger Seminars LEF, 2005)
LFT Import::2019-08-05 (1141)

Grundlagenuntersuchungen und Erarbeitung einer Methodik zur Herstellung maßgeschneiderter Halbzeuge auf Basis eines neuartigen flexiblen Walzprozesses - Vogel, Manfred (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2023)
One of the greatest social challenges of the 21st century is the mitigation of climate change. One approach that has become increasingly important in recent years, especially in the automotive industry, is holistic lightweight construction, which is increasingly pushing conventional manufacturing technologies in the area of forming technology to their limits. By applying the innovative process class of sheet bulk metal forming, functional components with a high degree of functional integration can be manufactured in a process-safe, energy-and cost-optimized manner. The use of process-adapted semifinished products in particular has proven to increase material efficiency. In particular, incremental forming processes show a high potential. The aim of the present work is therefore to develop a holistic process understanding for the production of tailored blanks by means of a new flexible rolling process. To derive physical relationships, a fundamental experimental process and influence analysis is carried out and, based on this, a holistic methodology for the manufacturing of a rotationally symmetrical material pre-distribution is derived. Using the knowledge gained, the transferability of the methodology to higher-strength material classes and varying semi-finished product thicknesses, as well as the usability of the semi-finished products in a downstream combined deep-drawing and upsetting process is evaluate

Grundlagenuntersuchungen zum Halbwarmmikroumformen - Egerer, Emil; Neudecker, Thomas; Engel, Ulf (Tagungsband zum DFG-Kolloquium im SPP 1074 am 11.-12.09.2001, 2001)
LFT Import::2019-08-05 (827)

Grundlagenuntersuchungen zum Presshärten höchstfester Vergütungsstähle - Merklein, Marion; Hoff, Cornelia; Lechler, Jürgen (6. Stahl-Symposium 2006 - Werkstoffe, Anwendung, Forschung, 06. April, 2006)
LFT Import::2019-08-05 (1304)

Grundlagenwissenschaftliche Untersuchung der kombinierten Prozesskette aus Umformen und Additive Fertigung - Schaub, Adam (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2019)
Nowadays, a rising amount of individualized products is requested due to a highly industrialized mankind with growing individual identities. Moreover, our generation faces the challenge of a cost, resource, and time efficient production of goods. One promising manufacturing approach to fulfill these needs is additive manufacturing. Though, additive manufacturing is also subject to some limitations such as a high amount of manufacturing time as well as limited efficiency of the power source. To overcome these disadvantages and to produce individual products a process chain combining conventional manufacturing techniques with conventional manufacturing techniques is presented within this work. The aim is to propound and analyze a process chain which fulfills today’s challenges of sustainable production. Within a determined process chain forming is combined with successive additive manufacturing to produce hybrid metallic parts. Therefore, laser and electron beam melting are investigated as well as various forming technologies such as bending, deep drawing and super plastic forming. As basis of this work these manufacturing technologies are analyzed with focus on their applicability and benefits for the combined process chai

Grundlagenwissenschaftliche Untersuchungen zum Kaltfließpressen kleinster metallischer Pin-Strukturen aus der Blechebene - Kraus, Martin (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2024)
Die Miniaturisierung von Produkten bei gleichzeitiger Integration mehrerer Funktionen ist ein aktueller globaler Trend, um Gewicht, Platz, Material und Kosten zu sparen. Jedes Jahr werden Milliarden metallische Mikrobauteile produziert, und die Tendenz steigt. Umformtechnische Verfahren bieten bei der Massenproduktion technologische, wirtschaftliche und ökologische Vorteile gegenüber anderen Fertigungsverfahren. Bei der Verkleinerung in den Mikrobereich treten jedoch Größeneffekte auf, welche die Formgebung, die Prozessstabilität, die Handhabung und die Werkzeugbeanspruchung negativ beeinträchtigen können. Das mehrstufige Kaltfließpressen aus der Blechebene kann die Auswirkungen der Größeneffekte mindern, aber der komplexe Materialfluss bringt auch Herausforderungen mit sich. Daher war es das Ziel dieser Arbeit, ein grundlegendes Verständnis für den Prozess zu schaffen, um Ingenieuren bei der Optimierung zu helfen und den Übergang zu industriellen Anwendungen zu unterstützen. Im Rahmen der Untersuchungen dieser Arbeit konnte nachgewiesen werden, dass durch die mehrstufige Umformung wesentlich filigranere Pin-Strukturen aus der Blechebene hergestellt werden können. Zudem wurde aufgezeigt, dass durch die Auswahl geeigneter prozess-, werkstück-, und werkzeugseitiger Einflussparameter die Materialausnutzung erheblich gesteigert werden kann. Die gemachten Handlungsempfehlungen zur Prozessoptimierung und dargelegten Anwendungsmöglichkeiten sollen dazu beitragen, das Verfahren in der industriellen Produktion effizienter und nachhaltiger zu gestalte

Grundlegendes Prozessverständnis zur Herstellung von Bauteilen mit texturierten Oberflächen durch Mikroprägen in einem kombinierten Umformprozess - Reck, Manuel (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2025)
Durch die steigende Nachfrage nach Bauteilen mit hoher Funktionsdichte gewinnen metallische Komponenten mit texturierter Oberfläche an Bedeutung. Texturierte Oberflächen sind häufig aus der Natur inspiriert und können verschiedene Funktionen wie eine reduzierte Reibung oder eine angepasste Benetzbarkeit bereitstellen. Konventionelle Herstellungsverfahren solcher Bauteile geraten durch lange Prozesszeiten und hohe Fertigungskosten bisweilen an ihre Grenzen. Im Rahmen dieser Arbeit wird daher ein kombiniertes Umformverfahren untersucht, das die Herstellung von Bauteilgrundkörpern mit der Texturierung der Oberfläche in einem ressourceneffizienten Prozess verbindet. Die Zielsetzung der Arbeit ist die Erarbeitung eines grundlegenden Prozessverständnisses der umformtechnischen Fertigung dünnwandiger Komponenten mit mikrogeprägten Strukturen in einem einstufigen Verfahren. Die Prozessanalyse erfolgt anhand der Untersuchung von bauteil- und prozessspezifischen Herausforderungen sowie der anschließenden Ableitung von Grenzen der Formgebung. Eine systematische Einflussanalyse zudem Aufschluss über die Wirkmechanismen der Prozesskombination. Darauf basierend werden Methoden zur Erweiterung der Prozessgrenzen erarbeitet und bereitgestellt. Im Hinblick auf den industriellen Einsatz wird das werkzeugseitige Verschleißverhalten in der Fertigung großer Stückzahlen untersucht. Aus den erzielten Erkenntnissen werden anwendungsnahe Empfehlungen für kombinierte Texturierungsprozesse abgeleite

Grundlegende Untersuchungen zum Einfluss fertigungsbedingter Eigenschaften auf die Ermüdungsfestigkeit kaltmassivumgeformter Bauteile - Zimmermann, Andrea (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2019)
Increased environmental awareness in society is leading to the adoption of more and more legislation and programmes to reduce energy demand and improve resource efficiency. With the help of cold forging, resource-efficient production of components with very good mechanical properties is possible. Within the scope of this work, a holistic characterization of the influence of different process steps of the cold forging process chain on the resulting component properties was carried out. The investigations focus on the component properties from the entire process chain of a multi-stage cold forging process with special consideration of different heat treatment methods. The basis for the systematic investigations is the holistic characterization of the properties of the components produced by forming technology. The investigations included strain hardening and hardness, topography and roughness, the microstructure of the material and the resulting residual stresses. At the same time, a numerical simulation of the forming process was carried out in order to analyse correlations between material flow, stress distribution and resulting component properties. On the basis of these findings, the dynamic strength was determined with the aid of test devices developed specifically for the component. Finally, an analysis of the influence of the production-related component properties on the dynamic strength was carried out. By correlating the component properties with the determined dynamic loads, it was possible to identify the fundamental influences and their interactions for different dynamic loads. Based on the gained knowledge, recommendations are given for the design of the processes for the targeted adjustment of the component properties. The investigations make it possible to use the advantages of cold-forged components and to consider not only static strength but also dynamic strength in the development proces

Grundlegende Untersuchungen zum Excimerlaserstrahl-Abtragen unter Flüssigkeitsfilmen - Roth, Stephan (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2008)
Im Rahmen der Arbeit wird ein Verfahren zur Verbesserung der Bearbeitungsqualität bei der abtragenden Bearbeitung von keramischen und metallischen Werkstoffen mittels UV-Laserstrahlung untersucht. Durch Aufbringung eines dünnen Flüssigkeitsfilmes während des Abtrags können Materialablagerungen und Schmelzgrate vollständig vermieden werde

Grundlegende Untersuchungen zum Kontaktzustand zwischen Werkstück und Werkzeug bei umformtechnischen Prozessen unter tribologischen Gesichtspunkten - Weidel, Stephan (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2010)
Friction in forming processes is influenced decisively by the contact state between tool and workpiece. Thus, this work focuses on the basic characterisation of the contact state at boundary friction conditions as well as the influence of lubrication. These findings represent the basis for a variety of industry relevant topics like the improvement of physically motivated friction models for numerical process simulation or the design of tailored surfaces for a specific adjustment of frictio

Grundlegende Untersuchungen zum Laserstrahlstrukturieren von Kaltmassivumformwerkzeugen - Popp, Uwe (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2006)
The tribological conditions in forming processes determine product quality as well as tool life. Within this work the influence of a laser textured tool surface on tribology is investigated. By applying a suitable surface topography the lubricant used during the process works better and remains for a longer period. As a result tool life is increased significantl

Grundlegende Untersuchungen zum Nd:YAG- Laserstrahlfügen von Silizium für Komponenten der Optoelektronik - Kaufmann, Stefan (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2002)
A variety of optical and electro-optical components for telecommunications are based on silicon as a substrate or chip material. Both for new, innovative components and for the continuous improvement of existing products, laser-assisted joining technologies are of great importance for supplementing conventional joining processes. This book describes the basics of laser beam joining of silicon using Nd: YAG laser radiation. After discussing the beam-material interaction and the process method for blind spot welding, the laser-assisted fixing of glass fibers in silicon V-grooves for the coupling of glass fibers to optical components is presented. Another focal point is the laser beam welding of silicon substrates, whereby cracks in the component can be avoided by means of a laser-assisted preheating proces

Grundlegende Untersuchungen zum Prozess- und Werkstoffverhalten bei schwingungsüberlagerter Umformung - Michalski, Markus (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2020)
The superposition of mechanical tool vibrations with frequencies in the ultrasonic range is an approach that enables a considerable reduction of forming forces. So far, however, the incomplete understanding of the detailed process behaviour constrains the technologies broad industrial application. The central purposes of this thesis are the identification of responsible mechanisms for the phenomenon of vibration-based softening and the investigation of the ultrasonic influence on material forming limits. Metallic materials of four different classes are tested: martensitic stainless steel X17CrNi16-2, mild steel S235JR, wrought aluminium AW-6082 T6 and cast aluminium AC-43400. Apart from the known effect of vibration-induced force reduction, substantial specimen heating was recorded in a fundamental process analysis. In addition, a strongly altered forming behaviour was observed. Thermal softening and material-related influences have been identified as crucial mechanisms regarding force reduction. With respect to the forming limits of metallic materials under the influence of ultrasonic vibration, a significant reduction was found for all investigated materials. For the practical application of the technology, this implies potentials concerning reduced tool and workpiece loading as well as a more flexible press selection. This applies in particular to less critical forming operations regarding material failur

Grundlegende Untersuchungen zum Prozessverhalten von Silizium als Werkzeugwerkstoff für das Mikroscherschneiden metallischer Folien - Hildering, Sven (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2017)
The trend towards further miniaturisation of metallic components causes high demands on tools for mechanical manufacturing processes. Traditional tool production methods reach their technical and economical limits. Consequently, within this work an alternative approach is chosen by applying silicon etching for manufacturing micro punches with a width under 100 μm. Based on experimental and numerical investigations the fundamental process behaviour of silicon tools for micro blanking of thin metal foils is explaine

Grundlegende Untersuchungen zur Erfassung der realen Vorspannung von armierten Kaltfließpresswerkzeugen mittels Ultraschall - Putz, Alexander (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2006)
This book presents the development of a measurement System based on ultrasonics for the Evaluation of the real prestressing conditions of shrunken Cold forging Tools. This enables the securing of prestressing conditions that have a significant influence on tool life already before the usage in the pres

Grundlegende Untersuchungen zur experimentellen Ermittlung und zur Modellierung von Fließortkurven bei erhöhten Temperaturen - Hußnätter, Wolfgang (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2008)
Within this thesis the theoretical and experimental fundamentals for the characterization of sheet metals under biaxial tensile stress conditions and at elevated temperatures have been built. By developing a novel setup in combination with an independent strategy for the evaluation of the onset of yielding the experimental determination of yield loci has been enabled. With the magnesium wrought alloy AZ31 as reference material various yield criteria have been investigated that build the basis for the implementation of the modeling of material behavior in the finite-element-simulatio

Grundlegende Untersuchungen zur Gradierung der mechanischen Eigenschaften pressgehärteter Bauteile durch eine örtlich begrenzte Aufkohlung - Horn, Alexander (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2022)
Das Presshärten ultra-hochfester Stahllegierung ist ein etabliertes Verfahren zur Fertigung sicherheitsrelevanter Karosseriekomponenten. Weiteres Leichtbaupotential bieten Bauteile mit maßgeschneiderten Eigenschaften. Im Fokus bisheriger Untersuchungen standen vor allem Prozessvarianten, um die Duktilität örtlich zu verbessern. Dem gegenüber gibt es bisher keine etablierte Verfahrensvariante, um bei gleichbleibendem Bauteilgewicht einen gegenteiligen Effekt, also eine lokale Festigkeitssteigerung, zu erzielen. Vielversprechend ist in diesem Zusammenhang der Prozess der Aufkohlung. Aufgrund des fehlenden Prozesswissens war die übergeordnete Zielsetzung der vorliegenden Dissertation die Erarbeitung eines grundlegenden Prozessverständnisses zur Gradierung der mechanischen Eigenschaften durch eine örtlich begrenzte Aufkohlung. Zu diesem Zweck wurden zunächst prozessseitige und halbzeugseitige Einflussfaktoren bei der Aufkohlung analysiert. Durch eine ganzheitliche Charakterisierung wurde unter anderem ein grundlegendes Prozesswissen erarbeitet. Darauf aufbauend wurde die Ausdehnung der entstehenden Übergangszone gradierter Bauteile und der Einfluss einer Gradierung auf die mechanischen Eigenschaften untersucht. Die abgeleiteten Erkenntnisse wurden anhand eines Musterbauteils verifiziert. Neben einer Übertragung der Prozessführung auf eine andere Legierung erfolgte zudem eine Bewertung des Potentials aufgekohlter Halbzeuge für den Presshärteprozes

Grundlegende Untersuchungen zur Herstellung hochfester Aluminiumblechbauteile in einem kombinierten Umform- und Abschreckprozess - Degner, Julia (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2020)
Mobility is the prerequisite for the economic and social development of our modern service and industrial society.To guarantee mobility also in the future, sustainable measures and strategies are needed to increase the effi-ciency of vehicles while at the same time reducing environmental pollution, such as CO2 emissions. One of these strategies is the weight reduction of vehicles based on light-weight strategies and materials. Due to the high strength and low density, the focus of research has recently been on high-strength aluminum alloys, as these can lead to further sheet thickness reductions compared to conventional aluminum alloys and realize light-weight constructions even in safety- and crash-relevant areas. However, the challenge is the limited formability of these alloys, which is why tempera-ture-assisted forming processes are usually used. A new approach is the combined forming and quenching process. By means of a heat treatment in combination with an immediate forming and simultaneous quenching, the production of sophisticated component geometries can be enabled, which in turn can be optimized to the highest strengths by means of ageing pro-cesses. The aim of this work was to generate a basic process understanding for the manufacturing of high-strength aluminum sheet metal components within the framework of a combined forming and quenching process. The focus was on the definition of boundary conditions during heat treatment on the basis of a sensitivity analysis, the process design based on a thermal and mechanical material characterization as well as the process analysis and evaluation to identify the potential of a combined forming and quench-ing process using a demonstrator componen

Grundlegende Untersuchungen zur Herstellung von Leichtbauverbundstrukturen mit Aluminiumschaumkern - Hahn, Markus (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2005)
In the automotive industry substantial measures were taken in recent years in terms of lightweight construction to minimize fuel consumption and emission output and to counteract the likewise growing vehicle weight according to the rising demands of customers for higher comfort and improved passenger safety. Sandwich components are characterized by high stiffness and at the same time low weight and can contribute to weight reduction. Aluminium foams due to their material properties show an excellent potential to be used as the core structures in such composites. However the forming properties of aluminium foams are very poor. Within this work the material behaviour and the forming properties of aluminium foam at elevated temperatures are investigated and an adapted process and tool layout for forming is developed. Furthermore suitable joining techniques are characterized and evaluated regarding to their applicability to enable manufacturing of sandwich components made of aluminium foam and sheet metal material

Grundlegende Untersuchungen zur Herstellung zyklisch-symmetrischer Bauteile mit Nebenformelementen durch Blechmassivumformung - Koch, Johannes Peter Karl (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2016)
The so-called sheet-bulk metal forming comprises the application of bulk forming operations on sheet metal. This new class of process facilitates the manufacturing of components with complex shape elements which are ready-to-assemble, e.g. synchronizer rings made out of steel. Research subject of the doctoral thesis are the fundamentals of the process- and tool design for the forming of gearings using sheet metal blanks as semi-finished parts. The realization of an adequate mould filling has been emerged as a main challenge. Therefore, inter alia, an approach to control the material flow with a local adaptation of the tribological conditions was developed and successfully teste

Grundlegende Untersuchungen zur umformtechnischen Herstellung von Halbhohlstanznieten aus hochverfestigenden Werkstoffen - Kuball, Clara-Maria (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2024)
Vor dem Hintergrund der Relevanz des Klimaschutzes hat die Transformation hin zu hocheffizienten, nachhaltigen Produktionsprozessen begonnen. Das Halbhohlstanznieten ist ein mechanisches Fügeverfahren, welches für die Realisierung von Leichtbau und Mischbauweisen von Bedeutung ist. Die Nietherstellung ist allerdings aufgrund der erforderlichen Wärmebehandlung und Beschichtung der Niete energie-, zeit- und kostenintensiv. Durch den Einsatz hochverfestigender nichtrostender Nietwerkstoffe wird die Nachbehandlung obsolet. Aufgrund der hohen Werkzeugbeanspruchung stellt die Umformung derartiger Stähle eine Herausforderung dar, weshalb ein umfassendes Prozessverständnis erforderlich ist. Das Ziel dieser Arbeit war daher die Erarbeitung eines grundlegenden Prozessverständnisses für die umformtechnische Herstellung von Nieten aus hochverfestigenden Werkstoffen. Schwerpunkte bildeten hierbei die Identifikation und Analyse von prozess- und werkstoffseitigen Einflussgrößen auf den Umformprozess und die Bauteileigenschaften. Dies erfolgte auf Basis eines kombinierten experimentell-numerischen Ansatzes. Der Machbarkeitsnachweis für die Herstellung von Nieten aus hochverfestigenden Werkstoffen wurde erbracht. Während bei konventionellen Nieten infolge der Wärmebehandlung homogene Eigenschaften vorliegen, weisen die neuen Nieten gradierte mechanische Eigenschaften auf. Somit wurde eine Ausgangsbasis für die Herstellung von Nieten mit für das Fügen maßgeschneiderten Eigenschaften geschaffe

Grundlegende Untersuchungen zur Verbindung von pressgehärtetem Stahl und Aluminium mittels Schneidclinchen - Merklein, Marion; Meschut, G.; Müller, Martin; Hörhold, R. (Tagungsband - 20. Sächsiche Fachtagung Umformtechnik, 2013)
LFT Import::2019-08-05 (1928)

Grundlegende Untersuchungen zur Verschleißcharakterisierung beschichteter Kaltmassivumformwerkzeuge - Schrader, Tobias (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2016)
For a prevention of early tool failure by wear in industrial practice of cold forging knowledge about wear behavior of coated tools is decisive. Thus, aim of this thesis is to develop a methodology for wear characterization of coated tools, which is based on a newly developed application-related wear test and a specifically developed approach for wear evaluation. Moreover, the methodology provides the basis for a load adjusted application of coatings. Tool costs are reduced considerably in companies by a specific enhancement of tool lif

Grundsatzuntersuchungen, mathematische Modellierung und Ableitung einer Auslegungsrichtlinie für Gelenkantriebe nach dem Spinnenbeinprinzip - Landkammer, Stefan (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2019)
Biologische Lösungsansätze versprechen großes Potential für den technischen Fortschritt. Für Robotikantriebe können Spinnenbeine als optimales Vorbild dienen, da sie einerseits Leichtbau, Kompaktheit und Sensibilität sowie andererseits kraftvolle, dynamische Bewegungen in sich vereinen und dabei essentielle Grundanforderungen an technische Gelenkantriebe erfüllen. Im Rahmen der Arbeit wurde, mit Hilfe von Grundsatzuntersuchungen und der Biology-Push-Methodik, erstmals der Transfer des antagonistischen Spinnenbeinprinzips in einen technischen Gelenkantrieb erreicht. Das Funktions-prinzip dieses neuartigen Roboterantriebs wurde mit mathematischen Modellierungen und experimentellen Verifikationen wissenschaftlich ausgearbeitet. Die Erkenntnisse dieser Analysen ermöglichten die Ableitung einer Auslegungsmethodik. Die Validierung erfolgte anhand eines spinnenartigen Laufroboters. Damit ist der Gelenkmechanismus als neues Antriebselement allgemeingültig anwendbar und in der Robotik als neuer Aktuator einsetzba

Hall measurement method for the detection of material defects in plastic-embedded permanent magnets of rotors - Brela, Matthäus; Michalski, Markus; Gebhardt, Hans Joerg; Franke, Jörg (IECON Proceedings (Industrial Electronics Conference), 2013)
The efficiency of electric drives is determined by the mechanical and magnetic properties of the functional elements, such as stator and rotor. Due to the electromagnetic interaction with the magnetic field, generated by the stator, the rotor transforms the magnetic energy into a rotational motion. It is characterized by its magnetization, its magnetic field strength, the field distribution and its geometric dimensions. The current challenge is to produce electrical drives with minimal loss. This requires ensuring the magnetic characteristics of the rotors. Errors that can occur during manufacture are cracks, blowholes or inclusions in the permanent magnet. Those can lead to commutation problems or to increased noise. For this purpose, a non-destructive and non-contact measurement method, based on the measurement of the magnetic field with Hall-effect sensors to detect defects in plastic-bonded permanent magnet rotors was developed. © 2013 IEEE.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Actuators and System Integration; Diagnostic and Prognostic; Fault Detection; Permanent Magnet Machines; Sensors

Handling of Microparts in a Multi-Station Former - Egerer, Emil; Engel, Ulf; van der Heyd, Gerhard (2nd International Conference euspen, May 27th -31st, Turin, 2001)
LFT Import::2019-08-05 (875)

Heating effect on the forming behaviour of high nitrogen steel in bulk forming - Kuball, Clara-Maria; Merklein, Marion (AIP Conference Proceedings, 2019)
As a result of the ongoing trend towards lightweight design in various industrial sectors like the automotive industry, mechanical joining methods become increasingly important. These methods make multi-material design possible, while thermic joining techniques reach their limits. Semitubular self-piercing riveting is a mechanical joining technology which allows joining dissimilar materials by using rivets as fasteners. The manufacturing of the rivets, however, is costly and time-consuming, as the rivets conventionally have to be hardened, tempered and coated after forming, in order to achieve adequate strength and corrosion resistance. By using high nitrogen steel for the rivets, these additional process steps are not necessary anymore. Hence, the rivet production becomes more efficient. Because of the strengthening, caused by strain hardening, high-strength parts can be produced by cold bulk forming of high-strength steels. Nevertheless, pressure-nitrided steels are still rarely used in cold bulk forming due to high tool loads, which is a major challenge for the manufacturing process. Under those circumstances, there is a need for new approaches to manufacturing with the aim of reducing the tool loads and realising the production of rivets made of pressure-nitrided steel. One possibility is forming at elevated temperatures below recrystallisation temperature. For this purpose, the influence of the temperature on the forming behaviour of high nitrogen steel is investigated. In this context, possible changes in nitrogen content caused by heating of the material and thereby induced negative effects on the material properties have to be evaluated. The results of compression tests at different temperatures demonstrate the distinct reduction of yield strength at elevated temperatures. Moreover, further investigations show that the heat treatment tends to result in a change of the nitrogen content determined using energy dispersive X-ray spectroscopy. However, the changing nitrogen content does not affect the strength of the heat treated material after cooling.
CRIS-Team Scopus Importer:2019-07-23

Herstellung beanspruchungsangepasster Aluminiumblechhalbzeuge durch eine maßgeschneiderte Variation der Abkühlgeschwindigkeit nach Lösungsglühen - Lechner, Michael (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2015)
Precipitation hardenable aluminum alloys currently belong to the most important lightweight materials. For this reason, they are applied in many fields of day-to-day life. However, the limited formability is still an unsolved challenge. Therefore, within this fundamental research project a new and innovative technique to improve formability of precipitation hardenable aluminum alloys was developed. Through the patented technology of Tailor Quenched Blanks, it is possible to achieve mechanical properties which are stress optimized for a required application, by applying a locally tailored quenching after solution heat treatmen

Herstellung funktionaler Blechkomponenten - Merklein, Marion; Opel, Simon; Schneider, Thomas (wt Werkstattstechnik - Online, 2010)
LFT Import::2019-07-29 (723)

Herstellung hochfester Aluminiumblechwerkstoffe mittels Accumulative Roll Bonding - Böhm, Wolfgang; Merklein, Marion (Internationale Konferenz "Neuere Entwicklungen in der Blechumformung", 2014)
Ein entscheidender Aspekt bei der Produktentwicklung nachhaltiger Erzeugnisse ist die Berücksichtigung der Energieaufwendungen während des Herstellungsprozesses, der gesamten Nutzungsdauer und für das Recycling. Um den Treibstoffverbrauch und damit den Schadstoffausstoß während der Nutzung von PKWs zu minimieren, ist der Leichtbau im Karosseriebereich eine vielversprechende Strategie. Das Ziel dabei ist die Reduktion der Wanddicke der Komponenten bei gleichzeitiger Sicherstellung der Crashanforderungen. Dies erfordert den Einsatz hochfester Leichtbauwerkstoffe. Ein innovativer Fertigungsprozess zur Herstellung von Aluminiumblechen mit gesteigerter Festigkeit ist das Accumulative Roll Bonding (ARB). Hierbei werden mehrlagige Bleche hergestellt, die ein nanokristallines Gefüge aufweisen. Neben einer signifikant gesteigerten Festigkeit und einer erhöhten Dehnratensensitivität weisen diese Blechwerkstoffe in der Regel eine reduzierte Duktilität auf. Im Sinne einer wirtschaftlichen Weiterverarbeitung dieser Werkstoffe zu Karosseriekomponenten müssen jedoch effiziente Umformtechnologien zum Einsatz kommen. Um das Formgebungsvermögen zu erhöhen, wird die Technologie der Tailored Heat Treated Blanks (THTB) eingesetzt. Dabei wird vor der Umformung durch eine Kurzzeitwärmebehandlung in bestimmten Platinenbereichen die Festigkeit definiert reduziert. Über die geeignete Positionierung der Wärmebehandlungszonen kann die Umformbarkeit der gesamten Platine gesteigert und der Einsatz dieser hochfesten, mehrlagigen Aluminiumblechwerkstoffe im Bereich der Karosseriefertigung ermöglicht werden. Darüber hinaus bietet der ARB-Prozess ein großes Potential für die Verarbeitung großflächiger Recycling-Blechwerkstoffe, die beispielsweise aus Dachelementen oder Motorhauben entnommen wurden. Dies ermöglicht die Herstellung von Aluminiumhalbzeugen mit gesteigerter Festigkeit, die dann für tragende Komponenten außerhalb des Sichtbereichs im PKW eingesetzt werden können. Zudem sind im ARB-Prozess energetisch effiziente und kostengünstige Materialverbunde durch die angewandte Prozessstrategie realisierbar. Hierbei können beispielsweise zur Einsparung von Primärwerkstoff bzw. zur Realisierung bestimmter Materialeigenschaften an der Außenseite aufbereitete Recyclingwerkstoffe und die gewünschten Aluminiumgüten miteinander durch Walzplattieren gefügt werden. Vorab ist jeweils durch eine gewisse Anzahl an ARB-Zyklen eine Verbesserung der mechanischen Eigenschaften denkbar.
EAM Import::2019-03-13

Herstellung maßgeschneiderter Aluminiumwerkstoffe - Lechner, Michael; Böhm, Wolfgang; Nguyen, Manh Hung; Merklein, Marion (Konstruktion, 2013)
LFT Import::2019-07-29 (1913)

Herstellung metallischer Kleinstteile - Eine Herausforderung für die Umformtechnik - Eckstein, Ralf; Tiesler, Nicolas; Egerer, Emil; Engel, Ulf (Idee-Vision-Innovation, 2001)
LFT Import::2019-07-15 (828)

Herstellung prozessangepasster Halbzeuge mit variabler Blechdicke durch die Anwendung von Verfahren der Blechmassivumformung - Opel, Simon (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2013)
The central objective of this work is the manufacturing of process adapted semifinished products with a variable sheet thickness by sheet-bulk metal forming. The properties of the semi-finished products are locally adapted by the application of the forming processes upsetting, orbital forming and rolling. Furthermore the potential for the use has been evaluate

Herstellung und Umformeigenschaften hochfester mehrlagiger Aluminiumlegierungen der 6000er-Serie - Herrmann, Jürgen; Merklein, Marion (Energie / Effiziente Verarbeitung zukunftsweisender Leichtbauwerkstoffe, 2017)
LFT Import::2019-08-05 (2224)

Herstellung von 3D-Kernverbunden mit zellularen Kernstrukturen aus Aluminium - Hahn, Markus; Otto, Andreas (Materialwissenschaft und Werkstofftechnik, 2000)
LFT Import::2019-07-15 (778)

Herstellung von Aluminium-Foam-Sandwich Tailored Blanks - Dörfler, Stephan Manuel; Otto, Andreas (Berichts- und Industriekooloquium 15./16. Oktober, 2003)
LFT Import::2019-08-05 (1010)

Herstellung von funktionsoptimierten Bauteilen im Presshärtprozess - Merklein, Marion; Lechler, Jürgen; Stöhr, Thomas; Svec, Thomas (Stahl und Eisen, 2010)
LFT Import::2019-07-29 (225)

Herstellung von Nebenformelementen unterschiedlicher Geometrie an Blechen mittels Fließpressverfahren der Blechmassivumformung - Gröbel, Daniel (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2019)
Current social and political aspects demand the reduction of the environmental impact by means of efficient manufacturing processes and weight optimized products. However, this requirement surpasses the limits of conventional production methods. One possibility to approach this challenge is the use of Sheet-Bulk Metal Forming processes in order to manufacture highly integrated, functional parts. Hence, the objective of this work is to create the required knowledge to enable the reliable production of the desired functional elements of different shapes on blanks by application of extrusion operations. For this purpose, a corresponding full forward- and a lateral extrusion process are designed and investigated by numerical and experimental means in order to identify and analyze influences on the process result. Subsequently and based on the ascertained findings, measures are investigated and evaluated to solve determined challenge

Herstellung von YBCO Massivmaterialien durch reaktives Flüssigphasensintern - Eßer, Gerd (Verbundtreffen Texturierte HTSL-Massivmaterialien, 1994)
LFT Import::2019-08-05 (629)

High-Feed Milling of Tailored Surfaces for Sheet-Bulk Metal Forming Tools - Hense, Rouven; Wels, Christoph; Kersting, Petra; Vierzigmann, Ulrich; Löffler, Maria; Biermann, Dirk; Merklein, Marion (Production Engineering, 2015)
The increasingly investigated and applied production process sheet-bulk metal forming (SBMF) has novel requirements for the forming tools, e.g., the need of an adaptive material flow at different areas of the tool for an adequate form filling. One new method to realize different, defined tribological conditions are tailored surfaces (TS). During the design of forming tools, it is imperative to have profound knowledge about the tribology between the tool and the workpiece. This article introduces structuring with high-feed milling tools as one possibility for influencing the material flow during forming processes and presents a ring-compression test for the quantification of the tribological conditions, which is adapted for SBMF. On the basis of various machined structures, surface parameters are analyzed to identify a correlation with the friction coefficient to gain knowledge about the mechanisms of TS and to be able to choose structures according to the needs of SBMF processes.
LFT Import::2019-07-29 (2062)
Keywords: High-feed milling; Sheet-bulk metal forming; Tribology

High Power Laser Beam Melting of Ti-6Al-4V on Formed Sheet Metal to achieve Hybrid structures - Ahuja, Bhrigu; Schaub, Adam; Karg, Michael; Schmidt, Roman; Merklein, Marion; Schmidt, Michael (Proc. of SPIE Vol. 9353, 93530X, 2015)
Motivated by the desire to combine the advantages of two manufacturing concepts, namely Additive Manufacturing and sheet metal forming, the concept of hybrid processes emerged. Laser Beam Melting process with its characteristic layer by layer fabrication methodology has already been proved to be successful in fabricating fully dense 3D structures with micro sized Ti6Al4V powder. The presented research focuses on direct fabrication of Ti6 Al4V Additive Structures on a thin pre-formed Ti6 Al4V sheet metal substrate. In the state of the art Laser Beam Melting process, fabrication of solid structures is done on a support structure attached to a thick conventionally manufactured base plate. The state of the art process also uses a 200°C pre-heating of the fabrication platform in order to reduce the effect of heat induced stresses on the fabricated structures. Within the hybrid fabrication concept, 3D structures are directly fabricated on a thin sheet metal and the thermodynamic conditions are significantly different in comparison to the conventional process. The research aims at understanding the fundamental aspects of the interaction between the formed sheet metal and additive structure determines the corresponding mechanical characteristics. The interaction process during the fabrication exposes the alloy locally to non-optimum thermal cycles and the research therefore aims to understand the various influencing factors involved during the fabrication process. The system technology modifications required to achieve the aimed fabrication are also discussed in the presented research. © (2015) COPYRIGHT Society of Photo-Optical Instrumentation Engineers (SPIE). Downloading of the abstract is permitted for personal use onl
Keywords: Additive Manufacturing; Hybrid Fabrication; Ti-6Al-4V; Sheet Metal Forming

High Power Solid State Lasers in Automotive Production: History and Challenges - Eßer, Gerd; Gigengack, T.; Jäckel, T.; Löffler, K. (Proceedings of the 5th LANE, 2007)
LFT Import::2019-08-05 (1439)

High-precision blanking of thin copper foils using uncoated and coated monocrystalline silicon punches - Hildering, Sven; Becsi, L.; Engel, Ulf; Merklein, Marion; Mescheder, U. (Proc. 8th Int. Conf. Multi-Material Micro Manufacture, 2011)
LFT Import::2019-08-05 (1655)