Celebrating 50 Years of Forming Technology "Impulses and Innovations in Metal Forming
on September 8 and 9, 2022
Established in 1972 as the Chair for Forming Technologies, it evolved into one of Germany’s largest, internationally renowned forming technology institutes over the past 50 years, which is characterized by a broad-ranging field of research and a high level of training for engineers and young scientists. Together with research institutes and industrial partners from Germany and abroad, innovative basic and application-oriented research results were achieved, which often optimized industrial practice through technology transfer. Trends such as improved form and dimensional accuracy, the extension of forming limits, increasing product variance, or the environmentally conscious manufacturing and design of products were taken up and technological developments such as more precise analyses and calculation methods, more accurate measuring techniques, lightweight construction, new materials, digitalization, and artificial intelligence were applied. The thematically extended research assignment and the significant growth in staff members were taken into account by founding the IUL in 2004.
We look forward to celebrating the institute's anniversary with numerous companions in Dortmund in 2022.
Project “Property controlled multi-stage hot sheet metal forming” to be continued in second Phase of the SPP2183
The SPP2183 "Property Control of Forming Processes" is intended to initiate a paradigm shift to closed-loop controlled forming processes. At the IUL, in cooperation with the Chair of Automatic Control of the CAU Kiel, a combined model- and data-based control of the product properties in multi-stage hot metal forming is investigated. In the first phase, control-oriented descriptions were developed for the thermo-mechanical process under the boundary conditions of a material with subordinate cooling rate sensitivity. In the now approved second phase (start: 01.01.2022), the considerations will be extended to alloys with higher complexity (cooling rate sensitivity).
Contact: Juri Martschin M. Sc.
Leuphana University Lüneburg awards honorary doctorate to Prof. Matthias Kleiner
Within the framework of the "Dies Academicus 2021", Professor Kleiner was awarded an honorary doctorate from Leuphana University on July 7, 2021. The IUL Institute Director has been the elected President of the Leibniz Association since 2014 and is on leave of absence from TU Dortmund University to perform his duties. He received an honorary doctorate from the Faculty of Economics for his scientific work in the field of engineering and his outstanding contributions to research and science management. The committee further emphasized that his research in the field of manufacturing engineering has resulted in a wide range of innovations and patents and his research approach is characterized by interdisciplinarity and cooperation. The laudatory speech was given by Prof. Ben Khalifa, Institute Director at the Institute for Product and Process Innovation at Leuphana University and alumnus of the IUL. Prof. Tekkaya congratulated on site in Lüneburg on behalf of the entire IUL team.
Students meet IUL academic staff
For more than 10 years, the IUL has been doing research on innovative teaching and learning concepts for mechanical engineering within the scope of various (international) projects together with its partners. Nevertheless, during the Corona pandemic the IUL also had to find new concepts for well-established events and needed to digitize in-person courses and lectures at short notice. However, how successful were these concepts from the students' point of view?
In order to obtain this decisive feedback, Professor Tekkaya invited students and academic staff of the IUL’s forming technology lecture for a dialogue on May 27. Not only possible activities and jobs for students at the IUL, but also the challenges of digital examinations and ideas for improving teaching at the institute were discussed. The goal should be to combine the advantages of face-to-face learning and digital teaching. Through the direct exchange between students and teaching staff, problems in the implementation of digital teaching were identified and helpful impulses for teaching after Corona could be taken up. In addition, the meeting laid the foundation for an intensified collaboration between students and scientists in basic and application-oriented research at the IUL.
Industrial doctoral student successfully completes doctorate at the IUL
A highly successful collaboration with industry reached another climax on March 25, 2021: Mr. Sebastian Heibel passed his oral examination on the topic "Damage and failure behavior of high-strength multiphase steels". The PhD student is an industrial PhD student of Daimler AG at the IUL. His doctorate was supervised by Prof. Tekkaya and Dr. Winfried Nester, Daimler AG.
The public PhD lecture was streamed online and found numerous listeners.
The IUL congratulates very warmly!
New KORESIL project launched: Concepts for the resource-efficient and safe production of lightweight structures
On February 15, 2021, under the direction of Prof. Dr.-Ing. habil. Maik Gude from the Institute of Lightweight Structures and Polymer Technology (ILK) at the TU Dresden, the research and development project "Concepts for the resource-efficient and safe production of lightweight structures (KORESIL)" was launched. The joint project of ILK (Dresden), LWF (Paderborn), IART (Freiberg), iwb (Munich) and IUL (Dortmund) focuses on socio-technical solutions for process chains with closed material cycles. In particular, production aids such as online Life Cycle Assessment (LCA), Augmented Reality (AR) and collaborating robots (cobotics) are the focus of the work, which aims to achieve resource-efficient production of lightweight structures and safe, attractive workplace design.
IUL Keynote presentation of the Techtank Conference 2020 is now availabl
In 2020, the (digital) Techtank conference was hold on the topic of “Flexible Production, with focus on forming and stamping”. In his keynote presentation, Prof. Tekkaya talked about “New Technologies at the IUL” to point out the incredible flexibility in forming.
“Techtank Conference is organised by Techtank in collaboration with the Swedish application center Stamping and Forming Center of Excellence. The Conference has been organized since 2015, and is an annual meeting place for manufacturing and engineering companies, research institutes and other organizations that want to keep up to date with current trends in innovative manufacturing for industrial use, with focus on forming and stamping.” (Source: https://www.techtankconference.se)
Watch the full keynote presentation here:
New project on prediction of geometry changes during spring production
On December 1, 2020 the new project “Development of a model to predict geometry changes in spring manufacturing based on plasticity theory considering heat treatment“. The research project is funded by the FSV and the AiF. A virtual kick-off meeting with 30 representatives of the project partners from the spring industry took place on January 28. Based on material characterization and experimental investigations of the elementary process steps of winding, heat treatment and pre-setting, an analytical process model of the entire manufacturing process is being developed in the project. The model is intended to enable the determination of residual stresses and geometry changes during the production of helical compression springs, thus facilitating the currently largely experience-based adjustment of automatic winding machines. In addition, a better understanding of the individual manufacturing steps and their influence on the product properties is to be gained.
Contact: Anna Komodromos M. Sc.
First doctoral examination at the IUL in 2021
On February 2, 2021, Mr. Sebastian Wernicke's oral doctoral examination took place on the topic of "Incremental sheet-bulk metal forming of load-optimized functional components". The PhD public lecture was streamed online and attracted a large audience. This was the 6th digitally conducted doctoral examination at the IUL.
The IUL would like to cordially congratulate Mr. Wernicke on completing his PhD!
First digital lecture delivered from the experimental area at the IUL
On December 17, 2020, the hall lecture at the IUL was held digitally for the first time. This special lecture is held every winter semester as part of the lectures “Fundamentals in Forming Technology” and “Forming Technologies II” in order to provide students with a practical insight into the experimental area. After a short welcome and introduction to the institute by Prof. Tekkaya, the approximately 100 students attending the Zoom meeting were able to participate in a virtual tour through the hall, while at the same time experiments on four experimental stands were streamed live. IUL staff members conducted experiments on parameter identification, rotary draw bending, incremental sheet forming, and adiabatic blanking. The students had the opportunity to ask questions and comment on what they had seen at any time.
DFG approves second funding period of TRR 188
In the SFB / TRR188 “Damage-Controlled Forming Processes”, research on the paradigm shift in forming technology can be continued until 2024.
The German Research Foundation (DFG) has decided to continue funding the Collaborative Research Center Transregio (TRR) 188. For the second funding period until the end of 2024, 11.4 million euros were approved. As initiator and spokesperson of the Collaborative Research Center, Prof. A. E. Tekkaya will regularly hand over the management to Prof. G. Hirt from the IBF at RWTH Aachen University starting from January 2021. Other institutions involved in the second funding period are the “Max-Planck-Institut für Eisenforschung” in Düsseldorf and the Institute for Applied Materials – Section “Materials and Biomechanics” at KIT in Karlsruhe.
Internal material damage occurs when metal is formed. Under the guiding principle that damage is controllable and not a failure, the CRC/TRR 188 investigates how this affects the product properties. Within the interdisciplinary cooperation between forming technology, materials science, materials testing technology, and mechanics, it is be shown that the product design does not have to take the nominal properties into account, but the actual production-induced product properties, including damage. The aim is to indicate the degree of damage to a component quantitatively, to control it, and to specifically adjust it along the process chain. This enables the manufacture of innovative lightweight products with tailored and guaranteed performance.