Fundamentals of the Incremental Profile Forming

在全球资源紧缺的情况下，制造适应载荷的轻型材的新制造技术变得越来越重要。为此，开发了增量型材成形(IPF)，它允许沿纵轴制造具有不同(负荷适应的)截面几何形状的型材。由于这种成形方法的新颖性，目前还不存在对工艺的基本了解。为了有效地应用该方法，体育基础的发展是本研究项目必不可少的一部分。最初，应在实验和数值研究的框架内确定该过程的机理。此外，还应分析不同工艺参数对成形行为的影响，并定义相应的工艺窗口。调查结果将得到分析方法的补充和支持。特别是建立了预测型材几何形状和成形力的解析模型。为了减小加工力和扩大IPF工艺的成形极限，下一步将使用叠加振动来修改摩擦行为。除了开发集成振动单元的工具外，还将进一步致力于基于模型的叠加振动渐进成形过程的描述。

In view of global shortage of resources, new manufacturing technologies for fabrication of load-adapted lightweight profiles are becoming increasingly important. For this reason, the Incremental Profile Forming (IPF) was developed, which allows the fabrication of profiles with varying (load-adapted) cross-section geometries along the longitudinal axis. Due to the novelty of this forming method, currently, a fundamental process understanding is nonexistent. For an effective application of the method the development of the physical bases is an essential part of this research project. Initially, the mechanisms of the process shall be determined in the frame of experimental and numerical investigations. Furthermore, the influence of different process parameters on the forming behavior shall be analyzed and corresponding process windows defined. The findings will be complemented and supported by analytical approaches. Especially the analytical models for predicting the profile geometries as well as the forming forces will be developed. In order to reduce process forces and to extend the forming limits of the IPF process, the friction behavior shall be modified by the use of superimposed oscillation in the next step. Beside the development of the tool with an integrated oscillation unit, the research work will further focus on the model-based description of the incremental forming process with superimposed oscillation.