Hot Sheet Metal Forming of aluminium

  Cross-die specimen hot-formed with gas in simulation and experiment Copyright: © IBF

The production of sheet-based outer and structural automobile components from ultra-high-strength aluminum alloys can be made possible by elevated process temperatures.


Hot Sheet Metal Forming of aluminium - Simulation-aided process design

Numerischer Zwilling Warmblechumformung LS-Dyna

Modern concepts of lightweight design and sustainability in the mobility sector can be realized by using high-strength aluminium alloys, especially for outer or structural automotive components. Hot forming at process temperatures of up to 600°C increases the formability of aluminium sheets, which enables the production of complex lightweight components. The use of pressurized gas as the sole or supporting forming medium can additionally improve the forming load distribution and extend the process limits. However, the process design of such gas-based or hybrid hot sheet forming processes is challenging due to the complex thermo-mechanical interactions, which is why the IBF has been engaged in the development of numerical simulation methods for the accurate modelling of these processes. In addition to the forming process design and optimization, inverse methods for boundary condition calibration and strategies for computational time optimization are also being developed.

 For further information, please contact Lisa-Marie Reitmaier.

Image: Numerical twin of a hybrid hot sheet metal forming process in LS-Dyna, Copyright: IBF

Hot Sheet Metal Forming of aluminium - Laboratory scale process design


The reliability and robustness of the currently developed numerical simulation methods can be ensured by a wide spectrum of validations. For this purpose, critical target variables from experimentally produced components and the numerical simulation are compared with each other. For the validation of simulation methods for modern aluminum hot sheet metal forming processes, the IBF has various complex experimental setups, through which pure gas-based axisymmetric, mirror-symmetric and non-symmetric parts as well as a hybrid deep-drawn and gas-calibrated benchmark parts can be formed. Target variables, such as sheet thinning, draw-in and form-filling, can be used for comparison with numerical simulation. In addition to modelling the forming processes at a laboratory scale for simulation method validation, critical final part properties such as local hardness distribution, microstructure development and material strength are quantified throughout the hot forming process chain.

For further information, please contact Tobias Teeuwen.

Image: Laboratory-scale gas-assisted hot deep drawing tool, Copyright: IBF