Fundamentals of the Incremental Profile Forming

考虑到全球资源的短缺，新的制造技术对制造适应载荷的轻量化型材变得越来越重要。因此，开发了增量轮廓成形（IPF），允许沿纵轴制造具有不同（负载适应）横截面几何形状的轮廓。由于这种成形方法的新颖性，目前还没有一个基本的工艺认识。为了有效地应用该方法，物理基础的开发是本研究项目的重要组成部分。首先，该过程的机制应在实验和数值研究的框架内确定。进一步分析不同工艺参数对成形性能的影响，确定相应的工艺窗口。研究结果将得到分析方法的补充和支持。特别是用于预测型材几何形状和成形力的解析模型将得到发展。为了减小工艺力并延长IPF工艺的成形极限，在下一步骤中应通过使用叠加振荡来修改摩擦行为。除了开发集成振荡单元的刀具外，研究工作还将进一步侧重于基于模型的叠加振荡增量成形过程描述。

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.