Fraunhofer Institute for Production Technology IPTResearch project "AGAH"
Thermally forming the component
In the sheet metal processing industry, the demand for high-strength steels with tight manufacturing tolerances is increasing. In principle, sheet metal components can be manufactured using cold or thermally assisted forming processes. The advantage of the latter process lies in the improved formability of the component. For example, significantly lower process forces have to be applied to process high-strength sheet steel when the component is heated locally than in cold forming processes. At the same time, smoother cutting edges can be achieved with thermally assisted machining than in the cold process. One problem with thermally assisted shear cutting and forming of high-strength steels, however, is the stability of the forming tools. Contact between the forming tool, also known as the active part, and the heated sheet metal results in increased thermal stress on the active part. This can result in material adhesion and thermal expansion of the tool components, which in turn leads to a loss of quality in the component. At the same time, thermally assisted processing reduces the service life of the active parts and, therefore, the efficiency of the production process. Cooling channels are integrated into the active part to compensate for unwanted deformation effects. These channels can be individually manufactured as complex as the respective application requires. This optimized tool solution could significantly improve semi-hot and hot machining processes.
Tempered tools to improve quality
In conventional tool manufacturing, the toolmaker inserts the cooling channels into the component by drilling or other machining processes. A new approach is being pursued in the "AGAH" research project: The research consortium plans to integrate cooling channels in forming toolsusing an additive process, which optimizes the channel guides and, if necessary, enhances the multi-sided flow for effective cooling. This approach is being applied to various sheet metal processing methods in the "AGAH" project. While the project partner FGW produces the tools using 3D printing, Fraunhofer IPT is responsible for evaluating the additive tools during the ongoing process. In doing so, the scientists are looking at which thermal and mechanical stresses the tool can withstand without causing signs of wear on the tool or quality defects on the component. Finally, the tool solution is tested for its cost-effectiveness in high-scale processes. The partners aim to increase the quality of machining processes with low tolerances and to prevent process scatter during production ramp-up.
Consortium
- Forschungsgemeinschaft Werkzeuge und Werkstoffe e.V. (FGW), Remscheid
- Institut für Werkzeugforschung und Werkstoffe e.V. (IFW), Remscheid
- Fraunhofer Insitute for Production Technology IPT, Aachen
Funding
The "AGAH" research project is funded by the Federal Ministry of Economic Affairs and Climate Action (BMWK) as a project of the Industrial Collective Research (IGF).
Funding reference: 23013 N