Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

Manufacturing of tailored blanks by orbital forming and flexible rolling (DFG SFB/TR73 - A1/1)

Project Status: finished


The production of semi-finished products is realized by the manufacturing processes orbital forming and flexible rolling. Besides rotational symmetric tailored blanks, the manufacturing of cyclic symmetric and asymmetric tailored blanks with a defined sheet thickness distribution is object of current researches. For this purpose, a defined movement of the material with on the one hand a local sheet thickness reduction and on the other hand a local sheet thickness increase has to be realized. Main aspects regarding this topic is the realization of higher sheet thickness gradients as well as small, locally restricted material thickenings. Two materials, a mild deep drawing steel and a high-strength steel are used for these investigations. In addition to the ad-justment of a defined sheet thickness, cur-rent investigations are targeting the di-rected adaption of the mechanical proper-ties by specifically altering the process pa-rameters. This can be used to realize a local strain hardening in selected areas of the tailored blank.


2014 TR73 A1 hd

Geometric properties and strain hardening of tailored blanks manufactured by orbital forming

Research Groups



    • Hildenbrand, P.; Lechner, M.; Merklein, M.:
      A new strategy for manufacturing tailored blanks by a flexible rolling process.
      Materials Science Forum 854(2016), pp. 99-105

    • Merklein, M.; Lechner, M.; Gröbel, D.; Löffler, M.; Schneider, T.; Schulte, R.; Hildenbrand, P.:
      Innovative approaches for controlling the material flow in sheet-bulk metal forming processes.
      Manufacturing Review 3(2016)2, pp. 1-17

    • Besserer, H.-B.; Hildenbrand, P.; Gerstein, G.; Rodman, D.; Nürnberger, F.; Merklein, M.; Maier, H. J.:
      Ductile Damage and Fatigue Behavior of Semi-Finished Tailored Blanks for Sheet-Bulk Metal Forming Processes.
      Journal of Materials Engineering and Performance 25(2016)3, pp. 1136-1142

    • Besserer, H.-B.; Hildenbrand, P.; Gerstein, G.; Rodman, D.; Nürnberger, F.; Merklein, M.; Maier, H. J.:
      Induction heat treatment of sheet-bulk metal-formed parts assisted by water-air spray cooling.
      Steel Research Int. 87(2016)9, pp. 1220-1227

    • Gröbel, D.; Schulte, R.; Hildenbrand, P.; Lechner, M.; Engel, U.; Sieczkarek, P.; Wernicke, S.; Gies, S.; Tekkaya, A.E.; Behrens, B.A.; Hübner, S.; Vucetic, M.; Koch, S.; Merklein, M.:
      Manufacturing of functional elements by sheet-bulk metal forming processes.
      Production Engineering: Research and Development 10(2016)1, pp. 63-80


    • Hildenbrand, P.; Schneider, T.; Merklein, M.:
      Flexible Rolling of Process Adapted Semi-finished Parts and its Application in a Sheet-Bulk Metal Forming Process.
      Key Engineering Materials 639(2015), pp. 259-266

    • Hildenbrand, P.; Sieczkarek, P.; Matthias, S.; Löffler, M.; Besserer, H.:
      Inkrementelles Umformen dünnwandiger Funktionsbauteile unter Einsatz prozessangepasster Halbzeuge durch Verfahren der Blechmassivumformung.
      In: Tagungsband zum 18. Workshop Simulation in der Umformtechnik & 3. Industriekolloquium Blechmassivumformung 2015 - DFG Transregio 73 (Edtrs.): Tekkaya, A. E.; Liewald, M.; Merklein, M.; Behrens, B.-A., Shaker Verlag Aachen, 2015, pp. 149-170

    • Gröbel, D.; Hildenbrand, P.; Engel, U.; Merklein, M.:
      Influence of tailored blanks on forming of cold forged functional elements in a sheet bulk metal forming process.
      In: Stahl-Institut VDEh (Edtr.): Proceedings METEC & 2nd ESTAT, 2015, published on CD

    • Hildenbrand, P.; Schulte, R.; Merklein, M.:
      New process strategies to manufacture tailored blanks out of DP600 by orbital forming.
      Applied Mechanics and Materials 794(2015), pp. 144-151

    • Merklein, M.; Gröbel, D.; Löffler, M.; Schneider, T.; Hildenbrand, P.:
      Sheet-bulk metal forming – forming of functional components from sheet metals.
      In: Y. Qin, T.A. Dean, J. Lin, S.J. Yuan, F. Vollertsen (Edtr.): Proceedings of the 4th International Conference on New Forming Technology, MATEC Web of Conferences, 2015, pp. 01001 1-12


    • Merklein, M.; Andreas, K.; Gröbel, D.; Hildenbrand, P.; Müller, M.; Noneder, J.; Zimmermann, A.; Schneider, T.; Vierzigmann, U.:
      Potenziale und Grenzen der Simulation in der Fertigungstechnik.
      In: simufact engineering GmbH (Edtr.): Tagungsband 15. RoundTable - Simulating Manufacturing, ISBN: 978-3-9813814-3-6, 2014, pp. 1-38

    • Merklein, M.; Hildenbrand, P.; Schneider, T.:
      Application of Process adapted semi-finished Parts for the Production of Thin-walled Components via Sheet-Bulk Forming.
      In: Kawalla, R. (Edtr.): AutoMetForm / SFU 2014, ACATRAIN e.V., 2014, pp. 58-66

    • Loderer, A.; Hausotte, T.; Steinmann, P.; Merklein, M.; Landkammer, P.; Hildenbrand, P.; Schneider, T.:
      Development of a feature adapted measurement evaluation strategy.
      In: PTB open access repository (Edtr.): MacroScale 2014 - Recent developments in traceable dimensional measurements, 10.7795/810.20150325P, 2014, pp. 1-13

    Letztes Update: 01.04.2016