Coordination Funds

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Production technology is in transition from automated systems to cyber-physical production systems (CPPS). These systems integrate information and planning systems spatially and temporally into the production facilities and are intended to enable robust and adaptable production. This also requires a rethink in the design of forming processes. Components with high reliability and durability are still mainly produced by forming. Forged high-performance components and formed sheet metal parts have applications in energy and transport technology as well as in vehicle construction, for example. Forming processes have evolved over time and have become increasingly automated. Control technology has mainly been used to control the motion sequences of the forming machines. Forming processes therefore run in a controlled manner and can only react to a limited extent to fluctuations in the workpiece or disturbances. For use in resilient factories of the future, controlled processes must be developed that can adapt to changing conditions. The property control of forming processes is necessary to adjust component properties within specifications and to reduce scrap. The challenge in developing property controlled forming processes lies in the non-linear and distributed effect of the tool on the workpiece. Forming processes must be viewed as temporally and spatially distributed systems in order to understand and control them. For the development of efficient controllers, the forming process must be described mathematically and made accessible for systematic development. This priority program aims to explore the scientific fundamentals of process-integrated property control of forming processes and to practically test and validate new approaches. The cooperation between forming technology and control technology enables the method-based design of controllable forming systems and the consideration of sensors and actuators in the system design. The first phase of the program demonstrated that forming processes can be developed specifically for property control. The second phase focused on the development of soft sensors and their integration into control strategies. The third phase focuses on the design of forming processes for property control and the quantitative verification of property control under near-production conditions. The program aims to go beyond the current state of the art and advance the development of property-controlled forming processes.