Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

Parameter based process optimisation of bending and blanking operations

Project Status: finished


The goal of the project was the development and qualification of a methodology for computer aided process design of blanking and bending operations for the production of safety-related components. The damage and failure behaviour of high strength steels was investigated experimentally in new developed laboratory tests. The process behaviour was analysed in several sensitivity analysis in numerical simulation, in order to generate the necessary data basis for the development of a process prediction program. This program provides the user the possibility to evaluate the expected damage in dependency of process relevant parameters and the used material. Consequently the process prediction program can be used in the design process to improve the product quality.

Steps for the development of the process prediction program using the example of the bending process

Research Groups



    • Degner, J.; Herrmann, J.; Junker, F.; Berendt, E.; Merklein, M.:
      Leichtbauwerkstoffe für den modernen Automobilbau.
      Zeitschrift Konstruktion 3(2018), pp. 50-54


    • Tsoupis, I.; Hildering, S.; Hagenah, H.; Merklein, M.:
      Werkstoffschädigung in der Prozesskette Schneiden - Biegen.
      In: Liewald, M.; Tekkaya, A. E. (Edtrs.): 17. Workshop Simulation in der Umformtechnik, Institut für Umformtechnik, Universität Stuttgart, 2014, pp. 73-89

    • Tsoupis, I.; Hildering, S.; Merklein, M.:
      Bending of high-strength low-alloyed steel with respect to edge crack sensitivity caused by shearing operations.
      Procedia Engineering 81(2014), pp. 712-717


    • Vatter, P.; Hildering, S.; Tsoupis, I.; Merklein, M.:
      Development of a damage prediction system for bending and cutting of high strength steels.
      Key Eng. Mater. 554-557(2013), pp. 2479-2486

    • Tsoupis, I.; Hildering, S.; Merklein, M.:
      Prediction of Damage in Small Curvature Bending Processes of High Strength Steels Using Continuum Damage Mechanics Model in 3D Simulation.
      Prod. Eng. Res. Dev. 7(2013)2-3, pp. 239-249

    • Hildering, S.; Tsoupis, I.; Merklein, M.:
      Process and Damage Behaviour of High Strength Steels in Shearing Operations.
      In: Buchmayr, B. (Edtr.): Tagungsband XXXII. Verformungskundliches Kolloquium, Lehrstuhl für Umformtechnik, Montanuniversität Leoben, 2013, pp. 89-94

    • Tsoupis, I.; Hildering, S.; Merklein, M.:
      Numerical investigation of small curvature bendability of high strength low alloyed steel in air and die bending processes.
      In: Hora, P. (Edtr.): Proc. IDDRG 2013, Institute of Virtual Manufacturing, ETH Zurich, 2013, pp. 183-188


    • Merklein, M.; Tsoupis, I.; Hildering, S.:
      Fertigung innovativer Bauteile aus hochfesten Stählen: Biegen und Schneiden – Risse vermeiden.
      Zukunftstechnologien in Bayern - Neue Materialien, Verfahren und Produkte (2012), pp. 28-31

    • Tsoupis, I.; Hildering, S.; Merklein, M.:
      Methodology for the analysis of the process behaviour of advanced high strength steels in bending and shearing operations.
      Key Eng. Mater. 504-506(2012), pp. 895-900


    • Kaupper, M.; Tsoupis, I.; Merklein, M.; Weidinger, P.:
      Characterization of damage and fracture of high strength steels within air bending.
      In: Akkök, M.; Budak, E.; Firat, M.; Kaftanoglu, B. (Edtrs.): Proc. 6th Int. Conf. and Exhibition on Design and Production of Machines and Dies/Molds, MATIM, 2011, pp. 71-76

    Letztes Update: 03.03.2015