INNOVATIVE SERVICES FOR INDIVIDUAL SOLUTIONS

With the ambition to help shape progress, we offer a wide range of services in all areas of metal forming technology, always state-of-the-art.
The access to the extensive equipment is unique, modern software programmes are self-evident and individual customization is our particular strength. With our experience and competent partners, we are able to offer you a complete package from one source. Of course, we also support you with individual solutions for your projects.

GENERAL CONTRACTOR

ALL-IN-ONE SOLUTIONS FROM ONE SOURCE

Our holistic approach and the direct proximity to research and science are the requirements for a unique form of cooperation: We offer you the complete solution for every type of forming application throughout the entire process – from process analysis and material characterization to series production readiness!

With access to extensive modern equipment, our wide-ranging know-how and many years of experience in the fields of material characterization, forming simulation, shearing and modern forming processes, we develop the optimum solution for every requirement. In close cooperation with selected partners, we develop and design tools and prototypes.
Even in complex processes, we remain the responsible contact partner for you in the form of a general contractor.

Material Characterization

MATERIAL CHARACTERIZATION WITH STATE-OF-THE-ART TESTING METHODS AND TECHNIQUES

Material characterization goes hand in hand with simulation. We carry out all tests and examinations with three focal points for comprehensive statements on the material: standard and extended tests of material testing as well as metallographic and tribological examinations. For this purpose, we have all the necessary equipment at our disposal.

Material Testing and Characterization

The knowledge of the behaviour during the forming process and in particular of its stress limits is decisive for the success of a component. For a characterization in accordance with standards, the Forschungsgesellschaft Umformtechnik uses the latest methods – in addition to standardized tensile and compression tests, which includes the analysis of material behaviour under stress during deep drawing, in the component edge areas as well as during bending and hemming.

These are in detail:

  • Recording of flow curves in uniaxial tensile tests at room temperature and at elevated temperatures
  • Recording of flow curves in a compression test with a compression plastometer
  • Determination of the yield curve in the tensile-tensile stress state in the cross tension test
  • Hydraulic deepening test (diameter 100 mm, 200 mm, 500 mm)
  • Erichsen test
  • Determination of the drawing ratio limit (punch diameter: 100 mm)
  • Tool and fixture design for material characterization
  • Recording of forming limit diagrams (linear/non-linear)
  • Determination of edge crack sensitivity (Diabolo test and hole expansion)
  • Bendability (Bending Limit Curve)

Metallographic Investigations

Especially their microstructure characterizes the physical properties of a formed component and the necessary forming tools. Alloy constituents, microstructure, grain size and much more in the interior and in the edge areas essentially determine the functional properties of the workpiece.

Our range of metallographic tests includes:

  • Surface digitization of tool surfaces and workpieces
  • Structural analyses of steels, aluminium and magnesium alloys
  • Investigation of tools and workpieces after damage and production disturbances
  • Investigation of new types of tool coatings
  • Analysis of precipitation mechanisms of aluminium alloys, effects of hot and cold ageing
  • Roughness measurements on surfaces of all kinds
  • Macro and micro hardness testing

Tribological Investigations

In many cases, the investigations on predominant tribological systems during the forming process contribute significantly to the understanding of elementary correlations in sheet and bulk metal forming.

In this area, we offer concrete solutions:

  • Determination of friction properties of sheet metal-lubricant combinations
  • Optimization of drawbead shapes and materials
  • Optimization of drawing and punching edge radii
  • Determination of the wear behaviour of tool materials and coatings
  • Characterization of tribo-systems
  • Tempered strip drawing test (flat, bead, with deflection)
  • Lubricant characterization
  • Endurance test with exemplary pressing processes (run of complete coils up to 300 mm width)
  • Determination of the friction properties of sheet metal-lubricant-tool combinations

Simulation

SIMULATION AS BASIS FOR METHOD PLANING

As experts in sheet and bulk metal forming, we use forming simulation as an important tool to gain insight into processes. This makes it possible to trace the stress during forming and finally to estimate the feasibility of a component. Using process variants and tolerances in the simulation, we are able to classify the process robustness for a product.
The forming simulation enables control with regard to qualitative and quantitative product properties – this includes information on sheet thickness, stress and strain distribution on the one hand and, at the same time, findings on crack and wrinkle development or the formation of skid and impact lines on the other.

Besides, springback analysis and the subsequent compensation are revealing aspects resulting from the simulation of sheet metal forming. On the basis of the determined surface pressure on the tool surface, tool tryout can be supported or accelerated. No matter which simultaneous representation of forming processes is required – we offer you the appropriate simulation programme. In addition, we have experienced employees with high demands, since we attach great importance to the experimental validation of our simulation results.

Forming Processes

EXPERIENCE IN THE DESIGN OF FORMING PROCESSES – FROM PROTOTYPE TO SERIES PRODUCTION

The key to the successful and economical production of formed components are sophisticated tooling and process concepts. For our customers in sheet metal and bulk metal forming, we offer our services from the first method or stage planning to the series method in cooperation with our selected partners. Depending on your requirements, we can also assist you in the development and design of components optimised for metal forming technology. Forming simulation plays an important role here, and our highly qualified team knows how to correctly interpret the results in order to derive both technical and economic improvements.

Years of experience in the design of forming processes for sheet and bulk metal forming have enabled us to support you in all enquiries – regardless of whether the initial design, virtual validation or prototype testing is involved. We also offer optimization of processes and forming tools so that you can tap and exploit your full potential.

Modern tools and processes enable increasingly filigree and complex component geometries, innovative regulation concepts enhance process reliability and new servo-driven presses expand the product range. All these developments contribute to improving economic efficiency and shifting previous process limits. Thus, completely new application possibilities for metal forming technology open up in the context of modern production. In doing so, we are pleased to support you with our experience, competence and know-how.

Shearing

INNOVATIVES SHEARING WITH OPTIMIZED PROCESSES

Sheet metal parts are widely used in almost all areas of life – in automobiles, domestic devices and, of course, in mechanical and plant engineering. In the manufacturing process, the high productivity speaks for shear cutting, especially for large quantities. However, conventional shear cutting has some weaknesses which can lead to difficulties or necessary reworking during further processing. With improved special techniques, the Forschungsgesellschaft Umformtechnik can solve such problems and offer practice-oriented approaches.

Optimization of Shearing Processes
The properties of the cut surface are of great importance for the further processing of sheared sheet metal. Negative influences, e.g. caused by work hardening or flaking, should therefore be avoided. In the area of an edge crack in punched components, trimming offers an approach to increase the formability of the cutting edge. However, our optimization measures start earlier: Thanks to extensive measuring techniques, we are able to compare the different processes and determine process limits. We are pleased to assist you in the analysis of your processes and help you to extend existing process limits with the latest research approaches. With comprehensive competence and many years of experience in the field of shearing, we offer optimal support in the design of your processes or individual solutions adapted to your requirements.

Wear and Endurance Test
With high productivity, shearing offers an enormous advantage compared to other cutting methods. The decisive factor here is the tool life or wear, which depends on the tool material, sheet metal material, oiling and cutting parameters. The extensive equipment of the Forschungsgesellschaft Umformtechnik enables us to carry out individual tests on strip or blank material and to evaluate the influence of material quality and tool. Due to many years of research cooperation with industrial partners, we can draw on extensive experience with various materials and tool materials. With this knowledge, we also offer a significant advantage for your special needs.

Process Analysis

PROCESS ANALYSIS: IN SPEC FROM THE VERY FIRST STROKE

A continuing trend is the combination of individualized products according to customer requirements in mass production, also known as mass customization. This requires a high degree of flexibility in planning so that the process functions flawlessly from the first stroke in order to avoid possible downtime. For more than 30 years, a team of experienced forming and punching experts has been carrying out process and tool analysis at our customers’ sites. The analysis of the forming process is followed by comprehensive support during the tryout process or tool commissioning up to series production.

The FGU uses various modern FEM calculation software to visualize the forming process step by step and thus gain a better understanding of the process.

We also offer comprehensive services for component analysis, which goes hand in hand with tool analysis:

  • Execution of forming analyses on components with the measuring systems GOM Aramis and GOM Argus
  • Determination of technological component properties such as stiffness, strength and bulge resistance
  • Determination of springback
  • Evaluation of surfaces using optical measurement technology
  • Improvement of the failure description (definition of suitable material characterization)
  • Component digitization and analysis with GOM Atos

CONSULTING WITH AN EYE FOR CONNECTIONS

We support you with solutions for your strategic questions in the company. The FGU is your contact for:

CONSULTATION

CONSULTING WITH AN EYE FOR CONNECTIONS

Valuable experience from sheet metal and massive forming also flows into our consulting services. Often it is about strategic issues in the company to fully exploit their own potential. These are above all:

  • Identification of optimization potential
  • Organization in the product areas
  • Technological and product-oriented topics
  • Market research / technology scouting
  • Literature and patent research
  • Analysis of cost structures

STEFAN LEYH, M.SC.
Deputy Technical Director,
Order and Project Management

email: leyh@fgu-mbh.de

Tel.: +49 711 226 38 72