Annual Report 2016 - Mechanical Engineering

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Metal Forming and Casting 275
Metal Forming and Casting
Process and material qualification for metal forming, blanking and casting
Prof. Dr.-Ing.
Wolfram Volk
n The Chair of Metal Forming and Casting focuses on the three pro-
duction processes: casting, blanking and metal forming. In 2016 over
40 scientists worked at the institute on research projects which vary from
fundamental research to industrial application.
Casting
The research group ‘Casting’ focuses on:
n Molding materials
n Residual stress analysis and material
characterization
n Tooling technology for (high pressure)
die casting
n Continuous and composite casting
The increased requirements for cast
components, regarding their stiffness
and rigidity combined with lighter weight,
demand a precise understanding of the
operational external loads. If these are
being overlapped with internal pro-
duction-related loads, such as residual
stresses, unexpected operation failures
can occur. Due to that, there are high
demands in terms of measurements refer-
ring to the internal, mechanical stresses
and temperatures primarily with regard
to the cooling process after casting. By
using specific, high temperature stable
fibre bragg gratings, for instance while
casting aluminium, tensions and tem-
peratures can be determined during the
solidification and cooling of aluminum
alloys. The sensor allows the determina-
tion of time- and temperature resolved,
multidimensional strain development for
the use of up to 800 °C in liquid aluminum.
That way, the cost intensive, complex and
limited neutron diffraction does not have
to be used.
Another trend in the automotive industry is
the use of die cast structure parts replac-
ing sheet metal parts. Due to their highly
complex geometries extensive research in
the field of tool design is required and was
carried out in several projects.
The research in the fields of continuous
casting and composite casting focuses on
the development of continuous compound
casting processes which saves production
steps, energy and material. Furthermore
basic studies on the formation of com-
Phone +49.89.289.13790
Contact The founding of the new Fraunhofer IGCV
in Augsburg and Munich was a highlight
in 2016. Its intention is to strengthen the
Fraunhofer production section as a holistic
research partner for industry. As a typical
Fraunhofer facility it fulfills the needs
of the economy and will be a valuable
partner for production companies. The
aims are to provide research and develop-
ment services to small and medium-size
companies and to establish strategic
cooperations with major enterprises.
Virtual production and simulation
Process stability and capability
New technologies and
processes in the field of
casting
New technologies and
processes in the field of
blanking
New technologies and
processes in the field of
metal forming
Mould concept and fiber positioning