Residual stress-controlled incremental forming of high-strength sheet metal components

In the knowledge transfer project for the DFG Priority Program SPP 2013, the Institute of Forming Technology and Lightweight Components, in a collaborative effort with the Chair of Materials and Surface Technology at Chemnitz University of Technology and Faurecia Autositze GmbH, is investigating the targeted adjustment of residual stresses aiming at increasing the cyclic fatigue performance for the single point incremental forming process. The subject of the study is the safety-relevant component geometries of a seat rail and a section of a rear seat frame made of the industrially used high-strength steels DP1000 and HC500LA (see Figures a and b). In addition, several simultaneously acting forming tools will be investigated with regard to process time, residual stresses, cyclic fatigue strength, and failure cases (see Figure c). Finally, the process extension of an oscillating forming tool will be examined with regard to altering the microstructure and the reduction of process forces (see Figure d).

Mamros, E.M., Maaß, F., Gnäupel-Herold, T.H., Tekkaya, A.E., Kinsey, B.L., Ha, J., 2025. Manipulating martensitic transformation and residual stress development in stress superposed incremental forming of SS304. Advances in industrial and manufacturing engineering 10. https://doi.org/10.1016/j.aime.2025.100161

Maaß, F., Hahn, M., Tekkaya, A.E., 2024. Controlling product properties by compressive stress-superposed incremental forming, in: Mocellin, K., Bouchard, P.-O., Bigot, R., Balan, T. (Eds.), Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity. Presented at the International Conference on the Technology of Plasticity, Springer Nature Switzerland, Cham , pp. 731–738. https://doi.org/10.1007/978-3-031-41023-9_73

Mamros, Elizabeth M., Polec, L., Maaß, F., Clausmeyer, T., Tekkaya, A.E., Ha, J., Kinsey, B.L., 2024. Examination of bending stress superposition effect on martensite transformation in austenitic stainless steel 304, in: Mocellin, K., Bouchard, P.-O., Bigot, R., Balan, T. (Eds.), Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity, ICTP 2023 - Volume 2. Presented at the International Conference on the Technology of Plasticity, Springer Nature Switzerland, Cham, pp. 475–485. https://doi.org/10.1007/978-3-031-40920-2_49

Mamros, E M, Tekkaya, A.E., Kinsey, B.L., Ha, J., Maaß, F., 2024. Using tensile and compressive stress superposition during incremental forming to manipulate martensitic transformation in SS304, in: 43st International Deep Drawing Research Group (IDDRG) Conference 2024. Presented at the International Deep Drawing Research Group (IDDRG) conference, IOP Publishing. https://doi.org/10.1088/1757-899x/1307/1/012006

Maaß, F., Hahn, M., Tekkaya, A.E., 2022. Setting residual stresses in tensile stress-superposed incremental sheet forming, in: Vincze, G., Barlat, F. (Eds.), Achievements and Trends in Material Forming. Presented at the ESAFORM, Trans Tech Publ., Zürich, pp. 655–662. https://doi.org/10.4028/p-232uip

Mamros, E.M., Maaß, F., Hahn, M., Tekkaya, A.E., Ha, J., Kinsey, B.L., 2022. Superposing tensile stresses into single point incremental forming to affect martensitic transformation of SS304, in: Thuillier, S., Grolleau, V., Laurent, H. (Eds.), 41st International Deep Drawing Research Group (IDDRG) Conference 2022, Lorient, France. Presented at the International Deep-Drawing Research Group. Conference, IOP Publishing, Bristol. https://doi.org/10.1088/1757-899x/1238/1/012085

Maaß, F., Dobecki, M., Hahn, M., Reimers, W., Tekkaya, A.E., 2021. Targeted control of component residual stresses through incremental sheet metal forming. Engineering research. https://doi.org/10.1007/s10010-021-00485-8