Tailored Testing

  Test for Measuring the Friction Coefficient Copyright: © IBF

The development of new materials and processes may also require the use and further development of innovative testing technologies. The institute offers a wide range of possibilities for this.

The research topics embedded in this cross-sectional area are assigned to different research groups and are presented below.


Testing Under Bending Load

Versuchsstand zur Biegeprüfung

Various forming processes apply an alternating bending load to the workpiece. Such changes in the load direction make the consideration of the material behavior under low cyclic loading necessary. In order to test materials under alternating loads, a test rig has been designed at the Institute of Metal Forming. The test rig offers the possibility to apply unidirectional bending as well as cyclic bending. A flexible tool enables a fast variation of bending radii and distance of the bending dies. The material data can be derived from an inverse simulation using the measured machine data of bending force and displacement.

For further information, please contact Pavlo Pavliuchenko.

Image: Test stand for bending loads, Copyright: IBF

Investigation of Bond Formation and Failure of Metallic Alloys

Rotglühende Stahlproben bei der Verbindungsuntersuchung

Roll bonding enables the targeted combination of different materials and thus their mechanical and thermal properties in a single material composite. However, the connection created under pressure load can tear up again due to shear stress at the end of the roll gap. Thus, industrial production requires very long process chains, which are often determined by trial and error. In order to allow for a knowledge based design of such process chains, a basic experiment, using the torsion plastometer TA STD 812, was developed at the Institute of Metal Forming to characterize bond formation and failure. In this test, the connecting partners are heated inductively and joined under combined pressure and shear stress. After bond formation, the strength can be tested at deformation temperature under a combination of tensile, compressive and shear stress. The procedure thus enables testing under near-process conditions.

For further information, please contact Tobias Plum.

Image: Hot glowing steel specimens during bond investigation, Copyright: IBF
  Investigation of bond formation and failure

Friction Determination With Extended Conical Tube-Upsetting Test

Rotglühende Rohrkegelprobe vor und nach dem Stauchen

The conical tube-upsetting test is used to determine the friction coefficients for different friction models. Similar to the ring compression test, which is also available at the institute, the geometric change of the specimen is measured and evaluated by means of nomograms. The conical contact surface suppresses the occurrence of static friction and thus enables more homogeneous test conditions, even under high prevailing friction. In addition, a blue line laser has been added to the test setup in order to record the contour change during forming. These measured values can be used on the one hand for the inverse determination of the prevailing friction and on the other hand for the examination of the change in friction during the compression process. The test setup allows the testing of workpiece temperatures up to approx. 1200 °C. In addition, the tools can be preheated to temperatures of up to 300 °C.

For further information, please contact Michel Henze.

Image: Glowing conical tube specimen before and after upsetting, Copyright: IBF

Hot-Gas-Bulge Test

Glühendes Stahlblech im gasbasierten Tiefungsversuch

The goal of the hot-gas-bulge test project is to deliver accurate material data for the virtual testing and design of hot stamping processes. Hot-stamping is a quite new process, which is mostly used by the automotive industry for the production of high strength components. The high strength levels are achieved by simultaneous forming and quenching of hot steel sheets with initial temperatures up to 950 °C.
For the material testing, a pneumatic bulge test is developed within this project. The bulge tests consists basically of two rings fixing a sheet metal. The sheet metal is then loaded with a controlled gas pressure, which causes the sheet to bulge through one of these rings. Although the controlled gas forming of sheets is challenging, flow curve in the temperature range of 600 to 950 °C can be obtained at constant strain rates of 0.5 s-1. Future goals are the increase of the strain rate up to 5 s-1 and testing of the meta stable austenite.

For further information, please contact Tobias Teeuwen.

Image: Annealed steel sheet in hot gas bulge test, Copyright: IBF
  Hot gas bulge test

Thermal Characterization of Surface Contacts

Versuchsstand zur Ermittlung der stationären Wärmeleitung

For the simulation of hot forming processes, the knowledge of the heat transfer between the tool and the work piece is of importance. Currently the determination of the interfacial heat transfer coefficient is carried out via inverse methods in transient condition, which sometimes provides only insufficient results. Therefore, a test stand for the steady state heat conduction is being developed at the IBF in cooperation with the Department for Industrial Furnaces and Heat Engineering. Thereby, various influencing variables such as atmosphere, contact pressure, temperature and surface roughness may be varied in order to model the corresponding processes as application-orientated as possible. Particular focus is placed on lower contact pressures at higher temperatures, which allows the modeling of processes such as annealing of coiled metal strips or the slab transport on the roller conveyors.

For further information, please contact Daniel Petrell.

Image: Test rig for determining the steady state heat conduction, Copyright: IBF