Fundamental Research and Process Development for the Manufacturing of Load-Optimized Parts by Incremental Forming of Metal Sheets – Incremental Sheet-Bulk Metal Forming (iSBMF)

In subproject A4 of the CRC Transregio 73, the main objective was the manufacturing of geometrically complex components from sheets with integrated functional elements by incremental forming operations. Adjusting the load capacity by thickening of the edge ensued the calibration of functional elements. It was investigated whether the strain paths resulting from different process strategies are usable for a targeted manipulation of the mechanical product properties. Numerical investigations of the iSBMF processes presented cyclic load changes. Experimental measurements of the resulting hardness revealed that it is not possible to fully utilize the strain hardening potential of the material observed in monotonous characterization. Another focus was the reduction of the high mechanical tool load by application of electrical pulses (see Figure a). Such pulses on locally insulated tools enable a high electrical current density J within the forming zone (see Figure b). This facilitates a temporary force reduction of more than 50% without losing strain hardening (see Figure c).