All completed projects

10/14/2025

Development of a continuous process for the intrinsic production of plastic-metal composite structures

Technology for the continuous production of hybrid profiles made of aluminum and polymer in a single process step.

01/01/2025

NUMISHEET 2025 – Scientific Benchmark – Material Under Control (MUC)

The NUMISHEET 2025 Scientific benchmark tested the methodologies of 19 industrial and academic entities worldwide in their ability to predict strain…

03/01/2023

Kinematic profile bending with locally heated cross-section for tailoring of mechanical properties

This project deals with the reduction of warping and the mechanical tayloring of open profiles in a profile bending process.

09/01/2022

Flexible tool design with shear thickening fluids in impulse forming processes

Flexible vaporizing foil actuator forming process by replacing rigid steel dies with additively manufactured shells supported by shear-thickening…

09/01/2022

Solid-state welding of oxide-containing aluminium surfaces in forming technology

Analysis of the influence of different hot extrusion conditions on the solid-state welding of oxide surfaces using an automated bond-strength testing…

10/01/2021

Prototype Development of a Device for Performing Equibiaxial Compression Tests for Material Characterization for Forming

a) Sketch of the biaxial compression test device, b) Stress state and strain state during biaxial compression

07/01/2021

Green Manufacturing – Analysis and Prediction of Emissions in an Industrial Hot Forming Process Chain

a) Concept of heat recovery, b) Proportion of part-specific CO2 emissions for an exemplary hot plate forged gear rack

07/01/2021

Increasing the Forming Limits by Heat-Assisted Bending below the Recrystallization Temperature

a) Design of the bending tool and part with cracks, b) Inductive heating before bending as well as component after bending

04/01/2021

Process Development and Technology Transfer of a Combined Forming Process for the Production of Graded Profiles for Lightweight Applications (ProLeit)

a) Combined rolling and drawing process, b) Formed workpiece (first tryout)

03/01/2021

Prediction of Wall Thinning during Rotary Draw Bending of Tubes

a) Estimation of wall thinning, b) Formability study using FLC from the numerical investigations

03/01/2021

Model Integration for Process Simulation

a) Damage locus, b) Validation in terms of air bending

03/01/2021

Analysis of a New Process for Continuous Hot Extrusion Utilizing the Theory of Similarity

Cycle of continuous hot extrusion, a-c) Direct extrusion, d-e) Indirect extrusion phase

02/15/2021

Joint Project: Concepts for the Resource-Efficient and Safe Production of Lightweight Structures (KORESIL)

Virtual reality model of the KORESIL process chain

01/01/2021

Forming of Additively Manufactured Sandwich Sheets with Optimized Core Structures

a) Large semi-finished sheet, b) Material-fit and form-fit joint, c) Shear strength of the connections and shear test

01/01/2021

Formability of High Temperature Stainless Steel Grades

Experimentally determined forming limit curves and geometry of utilized specimen

01/01/2021

Production of Sheets by Hot Extrusion of Aluminum Chips

Process chain for the production of chip-based sheets

01/01/2021

Development of an Efficient Physical-Based Modeling Approach for the Prediction of Microstructure in Extrusion Processes

Schematic workflow of the model development

01/01/2021

Passive Granular Medium-Based Tube Press Hardening

a) Process schematic, b) Required corner forming pressure, c) Cross section of a formed part

01/01/2021

Influencing the Evolution of Damage in Cold Extrusion

a) Experiments to determine the effect of load path changes and b) of heat treatments on damage

01/01/2021

Formability Limits of Advanced High-Strength Steels

Limits of the global (FLC) and local (FFL) formability in the prinicipal strain space

12/01/2020

Development of a Model to Predict Geometry Changes in Spring Manufacturing Based on Plasticity Theory Considering Heat Treatment

a) Process chain for the production of compression springs, b) Residual stresses in the wire cross section

09/01/2020

Analysis of the Application Potential of Roll-Clad MnB-Cr Steel Composites for Press Hardening

a) Hardness of the composite, b) Validation of the analytics

07/01/2020

Preparing the Standardization of the In-Plane Torsion Test

Overview of the four main fields of influences on the test results of the in plane torsion test.

06/01/2020

Hot Plate Forging of Load-Adapted Gear Racks

a) Schematic depiction of the plate forging process, b) Effective plastic strain distribution in the gear rack after forming

05/01/2020

Application and Analysis of Adiabatic Blanking

a) Comparison of strain localization, b) Effect of the strain rate sensitivity on forming energy

04/01/2020

Longitudinal Mechanical Joining of Extruded Aluminum Profiles with Increased Tightness Requirements

Longitudinal joining: equivalent plastic strain, contour comparison, and microstructure image

01/01/2020

Reducing the Stair Step Effect for Dies Manufactured by Layer-Laminated Manufacturing by Additive and Formative Post-Processing

Manufacturing the deep drawing tool by hybrid manufacturing with deep drawing depth of 21 mm and deep drawing ratio of 1.9

01/01/2020

Property-controlled multi-stage hot sheet metal forming

Property control in multi-stage press hardening enables the precise adjustment of the hardness and geometry of safety-relevant components.

01/01/2020

Process for Manufacturing Composite Components by a Combination of Deep Drawing and Cold Forging

a-d) Process with counter holder, e) Asymmetrically and f) Symmetrically encapsulated component

01/01/2020

Optimized Working Coil Windings for Electromagnetic Forming Employing Additive Manufacturing Techniques

a) Assembly-based hybrid coil, b) Single ring, c) Side supports, d) Comparison experiment/prognosis (sheet work piece)

01/01/2020

Functionalization of Additively Manufactured Hot Stamping Tools Using Ball Burnishing

a) Surface properties, b-d) Additive manufacturing of cooling channels: procedure and preliminary tests

12/01/2019

Media-Based Profile Shaping and Kinematic Bending in a Continuous Process Using a Graded Temperature Field

a) Hot-Tube-Bulge-Test setup, b) Determined forming limits at 1000 °C including the strain paths

09/01/2019

Improvement of Product Properties by Selective Induction of Residual Stresses in Incremental Sheet Metal Forming

Comparative structural strength test with in-situ corrosion

07/01/2019

Influence of the Multiaxial Bauschinger Effect in Cold Forging

Numerically determined residual stress distribution in cold-extruded parts and comparison with experiments

07/01/2019

Production of Flange-Shaped Components by Cold Forging of Composite Hot Extruded Semi-Finished Products

07/01/2019

Kinematic Profile Bending with Locally Heated Cross Section

01/01/2019

Composite Cold Forging of Cold-Forged Semi-Finished Parts

a) Process route for composite cold forging, b) Hollow demonstration part

01/01/2019

Incremental Sheet-Bulk Metal Forming by Application of Thermally-Controlled Grading Mechanisms

a) Cold/warm iSBMF, b) Required temperature field, c) Heated part, d) Resulting temperature field

07/01/2018

Forming by Locally Varying Vaporizing Actuators

Researched computation possibilities and selected experiment

01/01/2018

Shape Prediction and Improvement for Canning of Non-Round Tubes

Consistent prediction of the shape along the process chain of forming and canning

01/01/2017

Analysis of Strain Path-Dependent Damage and Microstructure Development for the Numerical Design of Sheet-Bulk Metal Forming Processes

Evaluation of the accuracy of different damage models regarding the occurrence of failure

01/01/2017

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

a) Schematic setup, b) Resulting current density, c) Measured impact on the forming force

10/01/2016

Development of a continuous process for the intrinsic production of plastic-metal composite structures

NUMISHEET 2025 – Scientific Benchmark – Material Under Control (MUC)

Kinematic profile bending with locally heated cross-section for tailoring of mechanical properties

Flexible tool design with shear thickening fluids in impulse forming processes

Solid-state welding of oxide-containing aluminium surfaces in forming technology

Prototype Development of a Device for Performing Equibiaxial Compression Tests for Material Characterization for Forming

Green Manufacturing – Analysis and Prediction of Emissions in an Industrial Hot Forming Process Chain

Increasing the Forming Limits by Heat-Assisted Bending below the Recrystallization Temperature

Process Development and Technology Transfer of a Combined Forming Process for the Production of Graded Profiles for Lightweight Applications (ProLeit)

Prediction of Wall Thinning during Rotary Draw Bending of Tubes

Model Integration for Process Simulation

Analysis of a New Process for Continuous Hot Extrusion Utilizing the Theory of Similarity

Joint Project: Concepts for the Resource-Efficient and Safe Production of Lightweight Structures (KORESIL)

Forming of Additively Manufactured Sandwich Sheets with Optimized Core Structures

Formability of High Temperature Stainless Steel Grades

Production of Sheets by Hot Extrusion of Aluminum Chips

Development of an Efficient Physical-Based Modeling Approach for the Prediction of Microstructure in Extrusion Processes

Passive Granular Medium-Based Tube Press Hardening

Influencing the Evolution of Damage in Cold Extrusion

Formability Limits of Advanced High-Strength Steels

Development of a Model to Predict Geometry Changes in Spring Manufacturing Based on Plasticity Theory Considering Heat Treatment

Analysis of the Application Potential of Roll-Clad MnB-Cr Steel Composites for Press Hardening

Preparing the Standardization of the In-Plane Torsion Test

Hot Plate Forging of Load-Adapted Gear Racks

Application and Analysis of Adiabatic Blanking

Longitudinal Mechanical Joining of Extruded Aluminum Profiles with Increased Tightness Requirements

Reducing the Stair Step Effect for Dies Manufactured by Layer-Laminated Manufacturing by Additive and Formative Post-Processing

Property-controlled multi-stage hot sheet metal forming

Process for Manufacturing Composite Components by a Combination of Deep Drawing and Cold Forging

Optimized Working Coil Windings for Electromagnetic Forming Employing Additive Manufacturing Techniques

Functionalization of Additively Manufactured Hot Stamping Tools Using Ball Burnishing

Media-Based Profile Shaping and Kinematic Bending in a Continuous Process Using a Graded Temperature Field

Improvement of Product Properties by Selective Induction of Residual Stresses in Incremental Sheet Metal Forming

Influence of the Multiaxial Bauschinger Effect in Cold Forging

Production of Flange-Shaped Components by Cold Forging of Composite Hot Extruded Semi-Finished Products

Kinematic Profile Bending with Locally Heated Cross Section

Composite Cold Forging of Cold-Forged Semi-Finished Parts

Incremental Sheet-Bulk Metal Forming by Application of Thermally-Controlled Grading Mechanisms

Forming by Locally Varying Vaporizing Actuators

Shape Prediction and Improvement for Canning of Non-Round Tubes

Analysis of Strain Path-Dependent Damage and Microstructure Development for the Numerical Design of Sheet-Bulk Metal Forming Processes

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

ELLI 2 – Excellent Teaching and Learning in Engineering Science