Bulk Metal Forming
Innovative development trends such as lightweight construction, increasing functional integration in components, and the economic and ecological need to shorten process chains are leading to new challenges in bulk metal forming. The research group of bulk metal forming is therefore investigating new approaches in the field of cold forming, whereby high-strength and ultra-high-strength components with high dimensional and shape accuracy as well as surface quality can be manufactured. In addition to fundamental component analysis, current research activities also focus on tooling and microforming technology. In addition to basic research projects, the spectrum also includes questions that make a direct contribution to industrial applications.
Members
Head of the Research Group
Nikolaos Rigas, M. Sc.
Gruppenleiter Blech- und Massivumformung
- Phone number: +49 9131 85-28309
- Email: nikolaos.rigas@fau.de
Members
Alina Biallas, M. Sc.
- Phone number: +49 9131 85-28309
- Email: alina.biallas@fau.de
Miriam Leicht, M. Sc.
- Phone number: +49 9131 85-28342
- Email: miriam.leicht@fau.de
Keyu Luo, M. Sc.
- Phone number: +49 9131 85-27956
- Email: keyu.luo@fau.de
Marion Vogel, M. Sc.
- Phone number: +49 9131 85-28315
- Email: marion.vogel@fau.de
Projects
Publications
2024
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Evaluation of Crack Propagation During Cyclic Bending of Wire Strip
14th International Conference on the Technology of Plasticity (Mandelieu - La Napoule, 24. September 2023 - 29. September 2023)
In: Katia Mocellin, Pierre-Olivier Bouchard, Régis Bigot, Tudor Balan (ed.): Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity, Cham: 2024
DOI: 10.1007/978-3-031-42093-1_18
2023
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Fundamental Investigations to Evaluate the Influence of Notching Processes on a Subsequent Cyclic Bending Process for the Production of Wire Cores
In: Journal of Manufacturing and Materials Processing 7 (2023), p. 24
ISSN: 2504-4494
DOI: 10.3390/jmmp7010024 - , :
Use of elastomers as pressure media for fatigue testing of cold forging tools
In: Procedia Structural Integrity 42 (2023), p. 66-71
DOI: 10.1016/j.prostr.2022.12.007
URL: https://www.sciencedirect.com/science/article/pii/S2452321622005649 - , :
Fatigue testing of cold forging tools using elastomer compression
In: CIRP Annals - Manufacturing Technology 72 (2023), p. 241-244
ISSN: 0007-8506
DOI: 10.1016/j.cirp.2023.03.007 - , , :
Numerical and experimental investigation of a backward extrusion process for forming geared components from coil
26th International ESAFORM Conference on Material Forming (Kraków, 19. April 2023 - 21. April 2023)
In: Materials Research Proceeding 2023
DOI: 10.21741/9781644902479-101 - , , , :
Experimental study of the potential for extending the process limits in multi-stage forming of micro gears from sheet metal by a local short-term laser heat treatment
Sheet Metal 2023 - 20th International Conference on Sheet Metal (Nürnberg, 2. April 2023 - 5. April 2023)
In: Materials Research Proceedings 2023 2023
DOI: 10.21741/9781644902417-38
2022
- , :
Interaction analysis of a notching and cyclic bending process
In: Manufacturing Letters 50th SME North American Manufacturing Research Conference (NMRC 50,2022) (2022), p. 167-173
ISSN: 2213-8463
DOI: 10.1016/j.mfglet.2022.07.022 - , :
Prestressing of cold forging tools for parts with functional elements
XL. Colloquium on Metal Forming (Zauchensee, 12. March 2022 - 16. March 2022)
In: Lehrstuhl für Umformtechnik, Montanuniversität Leoben, Martin Stockinger (ed.): XL. Colloquium on Metal Forming 2022 - , :
Local prestressing of cold forging tools by reinforcements with adapted interference
International Conference on Fatigue Design (Senlis, 17. November 2021 - 18. November 2021)
DOI: 10.1016/j.prostr.2022.03.022
URL: https://www.sciencedirect.com/science/article/pii/S2452321622002359 - , :
Prestressing of cold forging tools for parts with functional elements
(2022), p. 39 - 44 - , , , :
Investigation of the influence of material and sheet thickness on a three-stage process chain for cold forming of micro gears with a module of 0.1 mm
The 19th International Conference on Metal Forming (MF 2022) (Taiyuan, Shanxi, 11. September 2022 - 14. September 2022)
DOI: 10.1088/1757-899X/1270/1/012094
URL: https://iopscience.iop.org/article/10.1088/1757-899X/1270/1/012094 - , :
Investigation on tool properties for the production of components with micro textured surfaces
International Deep-Drawing Research Group Conference (Lorient, France)
In: IOP Conference Series: Materials Science and Engineering 2022
DOI: 10.1088/1757-899x/1238/1/012060 - , , , :
Investigation on micro textured tappets from design and production to the application properties
In: Proceedings of the Institution of Mechanical Engineers Part L-Journal of Materials-Design and Applications (2022)
ISSN: 1464-4207
DOI: 10.1177/14644207221124813 - , , , , , :
Influence of metal gear tooth geometry on load and wear within metal-polymer gear pairs
In: Applied Sciences 12 (2022), Article No.: 270
ISSN: 2076-3417
DOI: 10.3390/app12010270 - , , , :
Experimental Evaluation of the Feasibility and Reproducibility of a Novel Multi-step Forming Process for Cu-OFE Micro Gear Manufacturing Compared to Macro-scale Forming
In: Manufacturing Letters 50th SME North American Manufacturing Research Conference (NAMRC 50,2022) (2022), p. 183-189
ISSN: 2213-8463
DOI: 10.1016/j.mfglet.2022.07.024 - , :
Influence of Metal Flank Hardness of Machined and Cold Forged Gears on Wear within a Metal-Polyamide Gear Pair and Targeted Process Adaptation
In: Journal of Materials Engineering and Performance (2022)
ISSN: 1059-9495
DOI: 10.1007/s11665-022-07251-z - , :
Influence of Tailored Surfaces on the Surface Properties of Sheet-Bulk Metal Formed Parts
Steel in Cars and Trucks (SCT) (Milano, 20. June 2022 - 23. June 2022)
In: Proceedings of the Steel in Cars and Trucks (SCT) 2022
2021
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Evaluation of Material Behavior for Wire Strip under Cyclic Bending Load and Preparation of an Experimental Test Method
24th International Conference on Material Forming. (Liège, Belgium, 14. April 2021 - 16. April 2021)
In: Paper presented at ESAFORM 2021 2021
DOI: 10.25518/esaform21.3826
URL: https://popups.uliege.be/esaform21/index.php?id=3826 - , :
Material Model for the Production of Steel Fibers by Notch Rolling and Fulling
19th International Conference on Sheet Metal (SheMet 2021) (Erlangen, 29. March 2021 - 31. March 2021)
In: Merklein, M.; Duflou, J.; Fratini, L.; Hagenah, H.; Martins, P.; Meschut, G.; Micari, F. (ed.): Key Engineering Materials, Zurich, Switzerland: 2021
DOI: 10.4028/www.scientific.net/KEM.883.277 - , , , , :
Towards an holistic account on residual stresses in full-forward extruded rods: Experiment, modeling and simulation of forming and operation phases
In: Archive of Applied Mechanics (2021)
ISSN: 0939-1533
DOI: 10.1007/s00419-021-01917-1 - , , , , , , , , , , , :
Strategies for residual stress adjustment in bulk metal forming
In: Archive of Applied Mechanics (2021)
ISSN: 0939-1533
DOI: 10.1007/s00419-021-01903-7 - , , , , , , , , , :
Functional Analysis of Components Manufactured by a Sheet-Bulk Metal Forming Process
In: Journal of Manufacturing and Materials Processing 5 (2021), p. 1-18
ISSN: 2504-4494
DOI: 10.3390/jmmp5020049 - , , , :
Component residual stress control in forward rod extrusion by material flow and tribology—experiments and modeling
In: Forschung Im Ingenieurwesen-Engineering Research (2021)
ISSN: 0015-7899
DOI: 10.1007/s10010-021-00509-3 - , :
Influence of Material Delivery Condition on Residual Stresses and Part Properties During Forward Rod Extrusion
13th International Conference on the Technology of Plasticity (Grignano, 25. July 2021 - 30. July 2021)
DOI: 10.1007/978-3-030-75381-8_191 - , :
Analysis of stress pins for the local prestressing of cold forging tools
In: Production Engineering 15 (2021), p. 119-131
ISSN: 0944-6524
DOI: 10.1007/s11740-020-01012-4 - , :
Investigation on tailored blanks in a full forward extrusion process of sheet-bulk metal forming
24th International ESAFORM Conference on Material Forming (Liege, 14. April 2021 - 16. April 2021)
In: ESAFORM 2021 2021
DOI: 10.25518/esaform21.3673
URL: https://popups.uliege.be/esaform21/index.php?id=3673 - , , , , :
Forming of complex functional elements on sheet metal
In: M. Merklein, A.E. Tekkaya, B.-A. Behrens (ed.): Sheet Bulk Metal Forming, Springer Nature Switzerland AG, 2021
DOI: 10.1007/978-3-030-61902-2_2 - , , :
Adapted tool design for the cold forging of gears from non-ferrous and light metals
In: International Journal of Advanced Manufacturing Technology (2021)
ISSN: 0268-3768
DOI: 10.1007/s00170-020-06449-6 - , , :
Influence of the forming induced hardening on the wear behavior of aluminum gears within a metal-plastic material pairing and targeted adaption
49th SME North American Manufacturing Research Conference, NAMRC 2021 (Cincinnati, OH, 21. June 2021 - 25. June 2021)
In: Livan Fratini, Ihab Ragai (ed.): Procedia Manufacturing 2021
DOI: 10.1016/j.promfg.2021.06.078 - , , :
Forming of Components with Microgearings from Coil Material—Numerical Modeling of the Process Chain and Experimental Validation
In: Micromachines 12 (2021), p. 1456
ISSN: 2072-666X
DOI: 10.3390/mi12121456 - , , , :
Manufacturing of Tailored Blanks with Pre-shaped Involute Gearings by Using a Flexible Rolling Process and Its Application in a Sheet–Bulk Metal Forming Process
13th International Conference on the Technology of Plasticity, ICTP 2021 (Virtual, Online, 25. July 2021 - 30. July 2021)
In: Daehn G, Cao J, Kinsey B, Tekkaya E, Vivek A, Yoshida Y (ed.): Forming the Future - Proceedings of the 13th International Conference on the Technology of Plasticity, Cham: 2021
DOI: 10.1007/978-3-030-75381-8_46 - , , , :
Process Combination for the Manufacturing of Toothed, Thin-Walled Functional Elements by Using Process Adapted Semi-finished Products
DOI: 10.1007/978-3-030-61902-2_1 - , , , :
Analysis of the Influence of Surface Modifications on the Fatigue Behavior of Hot Work Tool Steel Components
In: Materials 14 (2021), p. 7324
ISSN: 1996-1944
DOI: 10.3390/ma14237324
2020
- , :
Applicability of Solid Lubricant Coatings in Cold Rod Extrusion of Stainless Steels
In: Defect and Diffusion Forum (2020), p. 95-100
ISSN: 1012-0386
DOI: 10.4028/www.scientific.net/DDF.404.95 - , :
Analysis of the stress state in non-axially symmetrical cold forging dies
In: Procedia Manufacturing 50 (2020), p. 307-313
ISSN: 2351-9789
DOI: 10.1016/j.promfg.2020.08.057
URL: https://www.sciencedirect.com/science/article/pii/S2351978920317558 - , :
Potential of Joining Dissimilar Materials by Cold Formed Pin-Structures
In: Journal of Materials Processing Technology 283 (2020), Article No.: 116697
ISSN: 0924-0136
DOI: 10.1016/j.jmatprotec.2020.116697 - , , :
Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements
In: Manufacturing Review 7 (2020), Article No.: 9
ISSN: 2265-4224
DOI: 10.1051/mfreview/2020003 - , , , , :
Ausgewählte Einflussgrößen auf die erzielbaren Verzahnungstoleranzen beim Kaltfließpressen.
In: Sandro Wartzack (ed.): Summer School Toleranzmanagement - Beiträge zur 4. Summer School - September 2020, Erlangen: 2020 - , , , , :
Verschleißmodellierung am Beispiel einer Polyamid-Stahl-Getriebepaarung für das prozessorientierte Toleranzmanagement
Summer School Toleranzmanagement (Erlangen, 28. September 2020 - 28. September 2020)
In: Sandro Wartzack (ed.): Beiträge zur 4. Summer School 2020 - , , , , :
Verfahrenskombination zur umformtechnischen Herstellung von verzahnten, dünnwandigen Funktionselementen aus prozessoptimierten Halbzeugen
23. Umformtechnisches Kolloquium Hannover (Hannover, 4. March 2020 - 5. March 2020)
In: Behrens B.-A. (ed.): Aktuelle Entwicklungen im Bereich der Umformtechnik - 23. Umformtechnisches Kolloquium Hannover 2020 - , , :
Analysis of the modification of tool surfaces by abrasive blasting and laser polishing
In: Defect and Diffusion Forum 404 DDF (2020), p. 124-131
ISSN: 1012-0386
DOI: 10.4028/www.scientific.net/DDF.404.124 - , :
Tool Sided Surface Modifications in the Industrial Environment
In: Marion Merklein, A. Erman Tekkaya, Bernd-Arno Behrens (ed.): Lecture Notes in Production Engineering (LNPE), 2020, p. 477-492 (Sheet Bulk Metal Forming)
ISBN: 9783030619015
DOI: 10.1007/978-3-030-61902-2_21 - , :
Analyse des tribologischen Einsatzverhaltens von modifizierten Werkzeugoberflächen
23. Umformtechnisches Kolloquium Hannover (Hannover, 4. March 2020 - 5. March 2020)
In: Bernd-Arno Behrens (ed.): Aktuelle Entwicklungen im Bereich der Umformtechnik 2020
2019
- , , , , , , , , :
A concept for process-oriented interdisciplinary tolerance management considering production-specific deviations
22nd International Conference on Engineering Design (ICED) (Delft, 5. August 2019 - 8. August 2019)
In: Proceedings of the 22nd International Conference on Engineering Design (ICED19), Cambridge, United Kingdom: 2019
DOI: 10.1017/dsi.2019.351
URL: https://www.cambridge.org/core/services/aop-cambridge-core/content/view/2DD6B2058F383E18C465C8731DBE9666/S2220434219003512a.pdf/concept_for_processoriented_interdisciplinary_tolerance_management_considering_productionspecific_deviations.pdf - , , , , , , , , :
Berücksichtigung von produktionsspezifischen Abweichungen im interdisziplinären Toleranzmanagement
Industriekolloquium der Forschergruppe FOR 2271 (Erlangen, 5. February 2019 - 5. February 2019)
In: Wartzack (ed.): Industriekolloquium der Forschergruppe FOR 2271, Stamsried: 2019
URL: https://www.archiv.mfk.tf.fau.de?file=pubmfk_5c6a7ad28207e - , , :
Investigations on Residual Stress Generation in Extruded Steel Components
9th Congress of the German Academic Association for Production Technology (WGP) (Hamburg, 30. September 2019 - 2. October 2019)
DOI: 10.1007/978-3-662-60417-5_8 - , :
Researching of commonalities and differences in cold forging of spur and helical gears
In: Production Engineering 13 (2019), p. 391-397
ISSN: 0944-6524
DOI: 10.1007/s11740-019-00887-2 - , :
Research of Adapted Tool Design in Cold Forging of Gears
In: International Journal of Material Forming (2019)
ISSN: 1960-6206
DOI: 10.1007/s12289-019-01508-0 - , , , , :
Mechanical joining without auxiliary element by cold formed pins for multi-material-systems
22nd International ESAFORM Conference on Material Forming (ESAFORM 2019) (Vitoria-Gasteiz, 8. May 2019 - 8. May 2019)
DOI: 10.1063/1.5112570 - , , :
Accuracy of conventional FE-Models in Bulk-Forming of Micropins from Sheet Metal
In: Journal of Micro and Nano-Manufacturing (2019), Article No.: 010902
ISSN: 2166-0468
DOI: 10.1115/1.4042965 - , , , , :
Investigations on residual stress generation in full-forward-extrusion
In: Production Engineering (2019)
ISSN: 0944-6524
DOI: 10.1007/s11740-019-00892-5 - , , , , :
Mechanisms of residual stress generation in full-forward-extrusion
In: Production Engineering (2019)
ISSN: 0944-6524 - , :
Influence of component design on extrusion processes in sheet-bulk metal forming
In: International Journal of Material Forming (2019)
ISSN: 1960-6206
DOI: 10.1007/s12289-019-01522-2 - , :
Comparison of extrusion processes in sheet-bulk metal forming for production of filigree functional elements
In: CIRP Journal of Manufacturing Science and Technology (2019)
ISSN: 1755-5817
DOI: 10.1016/j.cirpj.2019.05.004 - , , :
Berücksichtigung funktionsrelevanter Gestaltabweichungen bei der Auslegung von Umformprozessen zur Herstellung von Stirnrädern mit Sonderverzahung durch Fließpressen
Industriekolloquium der Forschungsgruppe FOR 2271
In: S. Wartzack (ed.): Industriekolloquium der Forschungsgruppe FOR 2271, Stamsried: 2019 - , , , , , , :
A methodology for the application of virtual evaluation methods within the design process of cold forged steel pinions
22nd International Conference on Engineering Design (, 5. August 2019 - 9. August 2019)
In: Proceedings of the 22nd International Conference on Engineering Design (ICED19), Delft, The Netherlands: 2019
DOI: 10.1017/dsi.2019.352 - , , , :
Influence of tribological conditions on application relevant component properties of cold forged gears
In: Production Engineering (2019)
ISSN: 0944-6524
DOI: 10.1007/s11740-019-00909-z - , , , :
Untersuchung des Einsatzverhaltens kaltfließgepresster Zahnräder
34. Jahrestreffen der Kaltmassivumformer (Düsseldorf, 27. February 2019 - 28. February 2019)
In: VDI Wissensforum GmbH (ed.): 34. Jahrestreffen der Kaltmassivumformer 2019 - , , , :
Einsatz numerischer Analysetools bei der Auslegung und Herstellung kaltfließgepresster Stahlzahnräder
In: Konstruktion (2019), p. 85-90
ISSN: 0720-5953 - , , , , , :
Targeted influencing of the mission-relevant component properties of cold-forged gearwheels
In: Konstruktion 2019 (2019), p. 94-98
ISSN: 0720-5953 - , , , , , :
Gezielte Beeinflussung der einsatzrelevanten Bauteileigenschaften kaltfließgepresster Zahnräder
In: Konstruktion (2019), p. 94-98
ISSN: 0720-5953 - , , , , :
Einfluss der fertigungsbedingten Gestalt und Struktur auf das Einlaufverhalten von Stahl-Kunststoff-Getriebepaarungen
Industriekolloquium der Forschergruppe FOR 2271 (Erlangen)
In: Industriekolloquium der Forschergruppe FOR 2271 2019 - , , , , , , :
New Approach on the Allocation of Wear Allowances - a Case Study
22nd International Conference on Engineering Design (ICED19) (Delft, 5. August 2019 - 8. August 2019)
DOI: 10.1017/dsi.2019.358 - , , , :
Effect of Surface Structure on Run-in Wear in Steel-Polyamide Gear Sets
In: Zeitschrift Kunststofftechnik 15 (2019), p. 370-391
ISSN: 1864-2217
DOI: 10.3139/O999.03052019 - , , , , :
Friction reduction in EHL contacts by surface microtexturing – tribological performance, manufacturing and tailored design
In: Industrial Lubrication and Tribology 71 (2019), p. 986-990
ISSN: 0036-8792
DOI: 10.1108/ILT-08-2018-0306
URL: https://www.emeraldinsight.com/doi/full/10.1108/ILT-08-2018-0306 - , :
Manufacturing of tailored blanks by orbital forming with a two-sided material thickening
In: Journal of Materials Processing Technology (2019), Article No.: 116491
ISSN: 0924-0136
DOI: 10.1016/j.jmatprotec.2019.116491 - , :
Flexible rolling of rotational symmetric tailored blanks with a two-sided thickness profile
47th SME North American Manufacturing Research Conference, NAMRC 2019 (Erie, PA, 10. June 2019 - 14. June 2019)
In: Livan Fratini, Ihab Ragai, Lihui Wang (ed.): Procedia Manufacturing 2019
DOI: 10.1016/j.promfg.2019.06.131 - , , , , , :
Maßgeschneiderter Werkzeugoberflächen in einem flexiblen Walzprozess
DOI: 10.25593/978-3-96147-280-2
(Conference report)
2018
- , , :
Investigation of Fatigue Strength of Tool Steels in Sheet-Bulk Metal Forming
The 21st International ESAFORM Conference on Material Forming
In: AIP Conference Proceedings 1960:1 2018
DOI: 10.1063/1.5035048 - , :
Manufacturing of process adapted tailored blanks by a flexible rolling process using the aluminum alloy AA6016
In: Key Engineering Materials 15 (2018), p. 1224-1231
ISSN: 1013-9826
DOI: 10.1016/j.promfg.2018.07.365 - , :
Analysis of combined extrusion micro coining process to manufacture microstructured tappets
In: Procedia Manufacturing 15 (2018), p. 272-279
ISSN: 2351-9789
DOI: 10.1016/j.promfg.2018.07.219
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