Table Of ContentLecture Notes in Production Engineering
Frank Vollertsen
Sybille Friedrich
Bernd Kuhfuß
Peter Maaß
Claus Thomy
Hans-Werner Zoch Editors
Cold Micro
Metal Forming
Research Report of the Collaborative
Research Center “Micro Cold Forming”
(SFB 747), Bremen, Germany
Lecture Notes in Production Engineering
Lecture Notes in Production Engineering (LNPE) is a new book series that
reportsthelatestresearchanddevelopmentsinProductionEngineering,comprising:
(cid:129) Biomanufacturing
(cid:129) Control and Management of Processes
(cid:129) Cutting and Forming
(cid:129) Design
(cid:129) Life Cycle Engineering
(cid:129) Machines and Systems
(cid:129) Optimization
(cid:129) Precision Engineering and Metrology
(cid:129) Surfaces
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excellence. Also considered for publication are lecture notes and other related
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original and timely, reporting the latest research and developments in all areas of
production engineering.
ThetargetaudienceofLNPEconsistsofadvancedlevelstudents,researchers,as
well as industry professionals working at the forefront of their fields. Much
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Springer’s print and electronic publishing channels. To submit a proposal or
request further information please contact Anthony Doyle, Publishing Editor
([email protected]).
More information about this series at http://www.springer.com/series/10642
Frank Vollertsen Sybille Friedrich
(cid:129) (cid:129)
ß ß
Bernd Kuhfu Peter Maa
(cid:129) (cid:129)
Claus Thomy Hans-Werner Zoch
(cid:129)
Editors
Cold Micro Metal Forming
Research Report of the Collaborative
“ ”
Research Center Micro Cold Forming
(SFB 747), Bremen, Germany
Final report of the DFG Collaborative Research
Center 747
Editors
FrankVollertsen Sybille Friedrich
BIAS—BremerInstitut für angewandte BIAS—BremerInstitut für angewandte
Strahltechnik GmbH Strahltechnik GmbH
Bremen, Germany Bremen, Germany
BerndKuhfuß PeterMaaß
Fachbereich Produktionstechnik Zentrumfür Technomathematik
UniversitätBremen UniversitätBremen
Bremen, Germany Bremen, Germany
ClausThomy Hans-Werner Zoch
BIAS—BremerInstitut für angewandte Stiftung Institut für Werkstofftechnik
Strahltechnik GmbH IWT
Bremen, Germany Bremen, Germany
ISSN 2194-0525 ISSN 2194-0533 (electronic)
Lecture Notesin ProductionEngineering
ISBN978-3-030-11279-0 ISBN978-3-030-11280-6 (eBook)
https://doi.org/10.1007/978-3-030-11280-6
LibraryofCongressControlNumber:2018967417
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Preface
This book gives an overview of the main research results, which are valuable to
enable a stable and understood mass production with lot sizes of more than
1,000,000 metal partsbymicroforming.Theresultshavebeengained intheyears
2007 to 2018 within the framework of the German Collaborative Research Center
(CRC) “Micro Cold Forming—Processes, Characterization, Optimization” (SFB
747 “Mikrokaltumformen—Prozesse, Charakterisierung, Optimierung”) of the
University of Bremen.
Chapter 1 of this book covers the motivation for the research on a reliable
production as well as information about the structure and the partners within the
collaboration and gives an overview of the main results, which were gained for
masteringeffectsoccurringinmassproduction.Besidesprocessesandmethodsfor
improving the forming processes itself, also the mastering of the complete pro-
duction line and the aspect of high flexibility in the design of processes and pro-
duction systems are addressed. Within this overarching description, references for
more detailed information in the following chapters are given.
Each of Chaps. 2–6 focuses on a field of competence covered by the CRC.
Fields of competence are micro forming, process design, tooling, quality control
and characterization as well as materials, especially designed for micro forming.
Withinthisframe,allsubprojectsofthethirdfundingperiodpresenttheirresultsin
Sects 2.1–6.4 in more detail, and each subproject is giving answers to a special
aspect, which allows mastering mass production of micro parts. The interdisci-
plinary cooperation between the researchers from production engineering, mathe-
matics and physics, who are working in several institutes, is an excellent base for
research in the demanding field of micro metal forming.
All the editors of this contributed book are the members of the executive board
oftheCRC.HeadoftheboardandoftheCRCisFrankVollertsen.Alltheauthors,
who contributed to this book, work in the relevant fields of the CRC. They are
directors or staff members of the collaborating research institutes. This book
extends the knowledge presented in the more fundamental book “Micro Metal
Forming” (Ed. F. Vollertsen, published by Springer).
v
vi Preface
A prerequisite for successful cooperation is the funding of manpower and
equipment, which was granted by Deutsche Forschungsgemeinschaft (DFG) and
the University of Bremen. We gratefully acknowledge this support. The editors
appreciate the powerful collaborations of the researchers within the CRC, which
have been the key for the successful work.
On behalf of the editors
Bremen, Germany Frank Vollertsen
November 2018 Head of the CRC (SFB 747 Mikrokaltumformen)
Acknowledgements The editors and authors of this book like to thank the Deutsche
Forschungsgemeinschaft (DFG), German Research Foundation, for the financial support of the
SFB 747 “Mikrokaltumformen—Prozesse, Charakerisierung, Optimierung” (Collaborative
ResearchCenter“MicroColdForming—Processes,Characterization,Optimization”).Wealsolike
to thank our members and project partners of theindustrial working group as well as ourinter-
nationalresearchpartners,fortheirsuccessfulcooperation.
Contents
1 Introduction to Collaborative Research Center Micro Cold
Forming (SFB 747). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Frank Vollertsen, Sybille Friedrich, Claus Thomy,
Ann-Kathrin Onken, Kirsten Tracht, Florian Böhmermann,
Oltmann Riemer, Andreas Fischer and Ralf B. Bergmann
2 Micro Forming Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bernd Kuhfuss, Christine Schattmann, Mischa Jahn, Alfred Schmidt,
Frank Vollertsen, Eric Moumi, Christian Schenck, Marius Herrmann,
Svetlana Ishkina, Lewin Rathmann and Lukas Heinrich
3 Process Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Claus Thomy, Philipp Wilhelmi, Ann-Kathrin Onken,
Christian Schenck, Bernd Kuhfuss, Kirsten Tracht, Daniel Rippel,
Michael Lütjen and Michael Freitag
4 Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Frank Vollertsen, Joseph Seven, Hamza Messaoudi,
Merlin Mikulewitsch, Andreas Fischer, Gert Goch, Salar Mehrafsun,
Oltmann Riemer, Peter Maaß, Florian Böhmermann,
Iwona Piotrowska-Kurczewski, Phil Gralla, Frederik Elsner-Dörge,
Jost Vehmeyer, Melanie Willert, Axel Meier, Igor Zahn,
Ekkard Brinksmeier and Christian Robert
5 Quality Control and Characterization . . . . . . . . . . . . . . . . . . . . . . . 253
Peter Maaß, Iwona Piotrowska-Kurczewski, Mostafa Agour,
Axel von Freyberg, Benjamin Staar, Claas Falldorf, Andreas Fischer,
Michael Lütjen, Michael Freitag, Gert Goch, Ralf B. Bergmann,
Aleksandar Simic, Merlin Mikulewitsch, Bernd Köhler,
Brigitte Clausen and Hans-Werner Zoch
vii
viii Contents
6 Materials for Micro Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Hans-Werner Zoch, Alwin Schulz, Chengsong Cui, Andreas Mehner,
Julien Kovac, Anastasiya Toenjes and Axel von Hehl
Contributors
Mostafa Agour BIAS—Bremer Institut für angewandte Strahltechnik GmbH,
Bremen, Germany;
Faculty of Science, Department of Physics, Aswan University, Aswan, Egypt
Ralf B. Bergmann BIAS—Bremer Institut für angewandte Strahltechnik GmbH,
University of Bremen, Bremen, Germany;
Physics and Electrical Engineering and MAPEX Center for Materials and
Processes, University of Bremen, Bremen, Germany
Florian Böhmermann Laboratory for Precision Machining—LFM, Leibniz
Institute for Materials Engineering—IWT, Bremen, Germany;
Leibniz-Institut für Werkstofforientierte Technologien—IWT, University of
Bremen, Bremen, Germany
Ekkard Brinksmeier LFM Laboratory for Precision Machining, Leibniz-Institut
fur Werkstofforientierte Technologien—IWT, Bremen, Germany
Brigitte Clausen Leibniz-Institut für Werkstofforientierte Technologien, Bremen,
Germany
Chengsong Cui Leibniz Institute for Materials Engineering—IWT, University of
Bremen, Bremen, Germany
Frederik Elsner-Dörge Labor für Mikrozerspanung—LFM, Leibniz Institute for
Materials Engineering—IWT, Bremen, Germany
Claas Falldorf BIAS—Bremer Institut für angewandte Strahltechnik GmbH,
Bremen, Germany
Andreas Fischer BIMAQ—Bremen Institute for Metrology, Automation and
Quality Science, University of Bremen, Bremen, Germany
Michael Freitag Faculty of Production Engineering, University of Bremen,
Bremen, Germany;
BIBA—Bremer Institut für Produktion und Logistik GmbH, Bremen, Germany
ix
