Sven Hübner's research while affiliated with Leibniz Universität Hannover and other places
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Publications (107)
The challenge implementing magnesium sheets as a lightweight material is to manufacture sheets with an acceptable formability at room temperature and sheet components with a suitable strength. The aim of this work is qualifying suitable alloys and their manufacturing process in a way that precipitation hardening is enabled after the final forming p...
The manganese-boron alloy 22MnB5 is particularly used for structural and safety-relevant parts in the automotive industry. Parts made from this alloy are usually produced using the hot forming process. Here, the sheet is heated to over 950 °C using an industrial roller hearth furnace. The heated sheet is then simultaneously formed and quenched in a...
Due to their good mechanical properties and low structural weight, multi-material structures are a promising approach in the automotive industry to lightweight design, body construction and functionalization. Especially metal and plastic are mainly combined to achieve improved properties of the final component compared to mono-material structures....
Hot stamping is a process for the production of ultra-high-strength components used in the automotive industry for passenger protection. In this process, cut blanks are heated in a roller hearth furnace, which is operated with gas, to approx. 950 °C in 8 to 10 min and then formed and quenched in a water-cooled tool. This extends the yield strength...
The focus of this research lays on the further development of the Polygon Forming Technology, which is already successfully used for cold forming components in the aerospace industry. One example is the fuselage shell of the Airbus Beluga XL. According to the current state of the art it is possible to incrementally form large cylindrical or conical...
Resource-efficient circular economy strategies can make a significant contribution to increase the environmental sustainability of products. Repair and refurbishment of damaged or obsolete components can be achieved through the use of additive manufacturing (AM) processes. However, the analysis of existing application examples shows that the applic...
Industrial product development today is faced with the challenge of achieving shorter creation cycles to keep up with international competition. This causes constantly changing requirements for the geometry of the components and thus for the used forming tools. These tools must be designed much faster so that customer requirements are met quickly,...
The use of fiber-reinforced plastics (FRP) is essential to meet future lightweight construction requirements in the automotive industry. Therefore, resource- and cost-saving as well as innovative manufacturing processes are needed, which enable large-scale series production. One example is the manufacturing of such components from glass mat-reinfor...
Deep drawing is a common forming method, where a sheet metal blank is drawn into a forming die by a punch. In previous research, conventional deep drawing was extended by the introduction of an additional force in the bottom of the cup. The force transmission initiates a pressure superposition in critical areas resulting in a delayed crack initiati...
The quality of deep-drawn parts is subject to uncontrollable fluctuations, triggered by material property variations and process deviations, which occur despite extensive quality controls along the entire process chain. Monitoring and controlling the draw-in of the sheet material—which is an indicator of a faultless deep drawing process—would allow...
The deep-drawability of a sheet metal blank is strongly influenced by the tribological conditions prevailing in a deep-drawing process. Therefore, new methods to influence the tribology represent an important research topic. In this work, the application of a process-integrated lubrication in a deep-drawing process is investigated. Most promising g...
Hot stamping is a well-established and frequently used manufacturing process in automotive body construction. The number of components manufactured in this way is continuously increasing. Hot stamping is used to produce components with a completely martensitic structure, resulting in high strength and hardness. These components are mainly used in s...
The aim of the investigations described in this article is to improve the clinching of aluminum die casting. The focus is on clinching an aluminum die casting alloy by local heat treatment and hence to join them in a process-safe manner. For this purpose, a heating strategy is used to warm up the die casting alloys to reduce temporarily and reversi...
The focus of this study is to improve the clinching ability of an aluminum die casting alloy with a sheet metal by local annealing in order to clinch them in a process-safe manner. For this purpose, the influence of three different heating strategies (heating plate, resistance heating and inductive heating) on the generation of clinching joints are...
In the hot-stamping process, a sheet blank, usually a manganese boron steel like 22MnB5, is heated up to the austenitising temperature in a roller hearth furnace and then formed in a cooled forming tool. This leads to tensile strengths of about 1500 MPa in the formed parts. The components produced in this process are used in particular in the autom...
This paper describes the investigation of a compression molding process for the production of a battery housing structure made of glass mat reinforced thermoplastic (GMT) for electric vehicles. The battery housing structure was scaled to a demonstrator geometry in the form of a battery shell. To enable variant-flexible manufacturing, a modular form...
The heat-treatable steel 22MnB5 is used in hot stamping processes to produce high-strength body-in-white components. In this process, sheet blanks are conventionally heated in roller hearth furnaces and then hot-stamped, whereby strengths of 1,500 MPa can be achieved. Disadvantages of this process are the low plastic deformation of the material in...
The increasing demand for resource-efficient production methods is driving the development of new technologies. Sheet bulk metal forming (SBMF) offers the possibility to combine sheet metal and bulk forming operations. This allows the production of complex functional components with secondary forming elements from sheet metal. Compared to other pro...
![Figure 1. Process-chain of the bolt anchor [19].](profile/Philipp-Mueller-28/publication/350856756/figure/fig1/AS:1012456067436547@1618399745360/Process-chain-of-the-bolt-anchor-19_Q320.jpg)
![Material data for X2CrNiN22-2 (UNS S32202) [25].](profile/Philipp-Mueller-28/publication/350856756/figure/tbl2/AS:1012456067461124@1618399745557/Material-data-for-X2CrNiN22-2-UNS-S32202-25_Q320.jpg)
Tools are of strategic importance for industrial manufacturing processes. Their behaviour has a great influence on the productivity of the process and the quality of the product. A material saving and efficient technique for processing metallic workpieces is cold forging. One major challenge of this production method is the handling of high contact...
Fringe projection profilometry in combination with other optical measuring technologies has established itself over the last decades as an essential complement to conventional, tactile measuring devices. The non-contact, holistic reconstruction of complex geometries within fractions of a second in conjunction with the lightweight and transportable...
In diesem Beitrag werden die Ergebnisse der sauerstofffreien konduktiven Erwärmung für das Formhärten, welches im Teilbereich A04 des Sonderforschungsbereiches 1368 behandelt wird, vorgestellt. Mit der entwickelten Prozesskammer können unbeschichtete Bleche sauerstofffrei, konduktiv erwärmt und beschichtet werden, die in einem miniaturisierten Stoß...
Techniken zur Steigerung der Formgebungsgrenzen in der Umformtechnik sind von hoher wirtschaftlicher Bedeutung. In dieser Arbeit wird eine Schwingungsüberlagerung im Krafthauptfluss eines Axialformprozesses zur Ausprägung einer Verzahnungsgeometrie untersucht. Die Auswirkungen der Schwingung auf die erzielbare Ausfüllung der Zahnkavitäten werden an...
Due to a low density and high tensile strength, the aluminum alloy EN AW 7075 T6 offers a high lightweight potential for structural components. Since its formability is limited at room temperature in the T6 temper state, the potential of this alloy for automotive bodies is only utilizable by adapted deep drawing processes. In recent years, process...
Within the scope of the subproject “Dynamic Process Forces” of the Collaborative Research Centre TCRC 73, a sheet-bulk metal forming (SBMF) process was developed to produce a demonstrator component with internal and external gearing from a sheet metal blank in three production steps. In the first step, a cup is deep-drawn. A hole is shear-cut in th...
Within the framework of the transfer project T05, the results from the sub-project A7 concerning a superimposed oscillation forming process will be transferred to an industry-oriented axial forming process of the company Felss Systems GmbH. Recursive axial forming serves as the reference model process. Here a gear geometry is axially formed on a ho...
The technology of sheet-bulk metal forming (SBMF) offers the possibility of manufacturing metal parts from a flat semi-finished product with functional secondary forming elements. Therefore, this technology provides the advantages of a resource-efficient production by shortening the process chain, saving materials and reducing the production costs....
In the scope of project A7 of the collaborative research center TCRC73 investigations of superimposed oscillation forming have been conducted. Positive effects regarding the reduction of plastic work, surface quality and mold filling in an ironing process could be demonstrated. Basic investigations also showed these effects for a compression proces...
A superimposed oscillation in the main force flow of a forming process is investigated. Therefore a tool system was developed. The oscillation in this system is generated by pulsating oil streams. As part of this research, the oscillation device is equipped with additional storage tanks, to generate a higher oil volume flow. The upgraded oscillatio...
Within the scope of the transregional collaborative research centre TCRC73, the effects of an oscillation superimposed forming process for the production of a demonstrator component are investigated. Previous studies in this field were limited to a consideration of the process-related parameters such as the influence of the plastic work and the fri...
Forming tools with tailored surfaces or functional surface modifications offer great potential for the adaption and optimization of forming processes. However, the interaction of the resulting tribological conditions with additional process oscillations and lubricants has not yet been sufficiently investigated. In the field of sheet-bulk metal form...
The high-strength boron steel 22MnB5 steel is widely used for automotive lightweight constructions. A novel approach is promising to tailor strength and ductility in the hardened condition using locally pre-tempered sheets for the hot stamping process. It results in the formation of locally soft spots where mechanical joining is subsequently intend...
A new sheet-bulk metal forming process for the production of bulk components out of a flat sheet has been developed. Superimposed oscillation has been applied to the new process. By this means, process limits regarding better mould filling were expanded, and forming forces could be reduced. In order to investigate the effects of superimposed oscill...
Producing complex sheet metal components in fewer process steps motivated the development of the innovative forming process called sheet-bulk metal forming (SBMF). In this process, sheet metal forming and bulk-metal forming are combined to create a unique forming process in which a component with external and internal gearing is produced in three p...
In cold forging processes as well as in sheet-bulk metal forming, vast contact stresses result in severe tool wear and thus in tool failures. In order to achieve a sustainable production, a new manufacturing process is developed within the subproject T06 in the transregional collaborative research centre 73 at the Institute of Forming Technology an...
This publication deals with finite element based modelling and the experimental validation of the flow characteristics of glass mat reinforced thermoplastic composite (GMT). Furthermore, the interaction of GMT and UD-Tape inserts is examined. The simulation model is set up in LS-Dyna. In order to model the high degree of deformation of the GMT the...
A 3D FEM-based virtual test-rig tool for the hybrid metal-composites clinching technology is developed and built in the commercial finite element software Abaqus. The proposed tool consists of two modules: a module to simulate the hybrid clinching process and another to predict the strength of the clinched joints. At first, experimental results con...
In this paper the acoustic emission behaviour during tensile tests of the materials DC06 and HCT600X is studied. Two steels with different characteristics (mild deep‐drawing steel DC06 and high‐strength steel HCT600X) are consciously chosen to show the influence of the material properties on the generated acoustic emissions. The acoustic emission b...
This research describes the development of a combined process of forming and thermal joining without adhesives of high strength steels and organosheets. In order to achieve cycle times below 20 s the temperature of the forming tool remains constant at 110 °C throughout the process. Thus, the removal of the component can take place immediately after...
Formgehärtete Bauteile sind aufgrund ihres Leichtbaupotenzials im Karosseriebau etabliert. Jedoch ist die mechanische und thermische Fügbarkeit aufgrund der hohen Festigkeit stark eingeschränkt. Ein Ansatz zur Verbesserung der Fügeeigenschaften ist die Erzeugung von weichen Fügezonen. Zur gezielten Einstellung von lokal angepassten mechanischen Eig...
The increasing use of hot-formed steels for structural components in lightweight construction requires solutions to create mounting points into the thin blank of high-strength steel. Compared to welding nuts, self-piercing nuts are often used due to advantages for the mechanical properties. The problems of setting these elements in hot-formed steel...
In lightweight hybrid constructions, where a high production rate is required, clinching technology demonstrates a sustainable process method to join hybrid metal-composite parts.
Clinching allows the mechanical fastening of independent entities through a cold forming process to be carried out without the need of any special surface treatment or...
Hot-stamped components are an important part in steel-intensive automobile lightweight design in which the use of the heat-treatable steel 22MnB5 has been established. However, the field of application is limited by the low elongation at break in the hardened state. In order to improve ductility and consequently the crash-performance, the formation...
In recent years, the automobile industry has been calling for new lightweight solutions to fulfill increasing ecologically requirements. A weight reduction of automobile body constructions is necessary to reduce fuel consumption and CO2 emissions. In order to reach this aim, new materials and novel forming processes are required. Also, the importan...
The use of Abrasive Water Jet (AWJ) cutting technology can improve the edge stretchability in sheet metal forming. The advances in technology have allowed significant increases in working speeds and pressures, reducing the AWJ operation cost. The main objective of this work was to determine the effect of selected AWJ cutting parameters on the Hole...
In this work, a parametric study of hybrid metal-composites clinching joints is performed via Taguchi’s design of experiments method to investigate the effect of tools geometry on the quality characteristics of the hybrid joints. Furthermore, a virtual test rig is presented to improve the design and optimization process of hybrid metal-composites c...
In different innovative markets, such as electro mobility and flexible electronics, among others, the mechanical joining processes based on sheet metal forming technologies are gaining a significant relevance due to their low cost and ease of automation as compared to traditional joining techniques of riveting, bolting, fastening, welding, etc. In...
Increasing diversity of types and decreasing batch sizes along with a growing complexity of products manufactured by forming technology result in new challenges for developers and designers. The construction of a full parametric model of a deep drawing tool in a 3D CAD system is usually considered time-consuming and associated with high cost, and t...
Aufgrund der hohen erreichbaren Festigkeit eignen sich formgehärtete Bauteile besonders zur Reduzierung der Massen von modernen Karosseriebauteilen. Die hohe Festigkeit führt allerdings zu einer eingeschränkten Einsatzmöglichkeit von mechanischen Fügeverfahren. Daher soll die Duktilität des Blechwerkstoffs während des Formhärtens genutzt werden, um...
To realize a dry sheet metal forming process, α-Fe2O3 oxide layers were investigated regarding their friction characteristics, wear behavior and surface energy depending on different surface qualities of the specimens examined. The oxide layers were generated in a new hybrid batch furnace. The layer generation on all specimens of the tool steel 1.2...
This research describes the development of a fully automated forming process of continuous FRP to assemble a down scaled battery tray for a plug-in-hybrid automobile. The paper presents the results of forming experiments and a restraint approach to avoid wrinkling, an FEM forming simulation to detect the wrinkling behavior, shear effects and temper...
The increased use of high and ultra-high strength steel and materials with a high adhesion tendency leads to higher demands regarding the wear resistance of forming tools. A promising approach addressing both challenges is to apply MoS2 dry film lubricant coating systems to the tool surface. These coatings reduce friction and the use of drawing oil...
In the household appliance industry piecework coating of body components has been successively substituted by usage of coil-coated sheets. For components with low strains or components not visible for the customer and therefore with no requirements concerning the visual impression these organic-coated materials bear a proper possibility for cost sa...
There is a strong trend in the automotive industry to reduce car body-, chassis- and power-train mass in order to lower carbon emissions. More wide spread use of lightweight short fiber reinforced polymer (SFRP) is a promising approach to attain this goal. This poses the challenge of how to integrate new SFRP components by joining them to tradition...
Acoustic emission (AE) is a non-destructive testing method with a high potential for quality and process monitoring in sheet metal forming. In this paper the possibilities and limitations of this testing method with regard to sheet metal forming are presented. For this purpose several rectangle cups were manufactured from the low carbon (DC06) as w...
Aluminum alloys of the 7000 series possess high lightweight potential due to their high specific tensile strength combined with a good ultimate elongation. For this reason, hot-formed boron-manganese-steel parts can be substituted by these alloys. Therefore, the application of these aluminum alloys for structural car body components is desired to d...
This paper presents the results and analysis of wear investigations carried out on a wear test bench with
high strength sheet metal DP600þZ drawn over selectively oxidised α-Fe2O3 tool steel surfaces. Wear
investigations were carried out with several selectively oxidised specimens by varying the pulling and
counter force, and thus the surface press...
This publication describes a new quick and economical method for the simulation of tool wear in the deep drawing and stretch forming of steel sheets in the area of the drawn edge. This method also allows a comparative evaluation of the properties of different tool materials versus reference materials. In order to reduce the amount of required test...
The paper presents results of wear investigations of thermally oxidised tool steel specimens with an α-Fe2O3 coating. The friction reducing ability of α-Fe2O3 layers on tool steel was shown in previous studies. Reduced friction and the layer’s stability are prerequistes to realise a dry sheet metal forming process that avoids the use of additional...
Der Fachartikel befasst sich mit der Umformbarkeit von höchstfesten Aluminiumlegierungen der 7xxx-Reihe. Diese haben eine hohe spezifische Festigkeit, weshalb sie ein großes Leichtbaupotenzial besitzen. Eine Umformung bei Raumtemperatur ist allerdings nur bedingt möglich und somit ein Einsatz im Automobilkarosseriebau derzeit kaum umsetzbar. Daher...
This research describes the development of a combined one-step process of complex organic sheet forming and GMT (Glass Mat Thermoplastics) compression molding which can be integrated in processes using conventional stamping technology. Hence, no additional injection molding step is required. Compression molding allows adding a third dimension to th...
Within deep drawing processes, welding represents an innovative approach to optimising the branched process chains which entail uneconomic process steps in production and transport lines. Previous applications of thermal joining processes in presses required a downstream process step for joining standardised functional elements such as nuts. Within...
Due to increasing economic and ecological restrictions, conventional sheet and bulk forming operations often reach their limits with regard to part weight and functional integration. One solution to meet those challenges is provided by sheet-bulk metal forming (SBMF) processes. SBMF is defined as the application of bulk forming operations on sheet...
Sheet-bulk metal forming processes combine conventional sheet forming processes with bulk forming of sheet semi-finished parts. In these processes the sheets undergo complex forming histories. Due to in- and out-of-plane material flow and large accumulated plastic strains, the conventional failure prediction methods for sheet metal forming such as...
Adhesively Bonded Blanks are manufactured using a method for combined forming and bonding of locally reinforced parts for body-in-white in the automotive and truck industry. The method allows lightweight constructions with steel sheets by generally reducing the thickness of body parts and compensates stiffness as well as strength by steel grades of...
Processes of the new production technology sheet-bulk metal forming allow a fast and efficient near-net-shape forming of highly complex parts. Thus the need of energy and raw material as well as the production cycle time can be reduced. In order to guarantee these advantages by avoiding scrap and moreover to ensure the parts’ geometrical requiremen...
The new manufacturing technology sheet-bulk metal forming (SBMF) combines the sheet metal forming and bulk metal forming techniques. At the Institute of Forming Technology and Machines (IFUM), a new multistage SBMF process is being developed. In order to reduce the friction and improve the dimensional accuracy of the parts, superimposed oscillation...
The paper presents results of a FEA-based tool design optimisation for a clinching process with an open multiple-part die. The studied materials are the bake-hardening steel CR240BH (1.5 mm) on the punch side and the die-cast aluminium alloy AlSi10MnMg (2.95 mm) on the die side. The objective of the optimisation was to minimise probability of crack...
Sheet-bulk metal forming is a manufacturing technology, which allows to produce a solid metal component out of a flat sheet. This paper focuses on numerical and experimental investigations of a new multistage forming process with compound press tools. The complete process sequence for the production of this solid metal component consists of three f...
Press-hardened profiles are used e.g. for automotive applications in order to improve light weight construction due to the high reachable strength. The application of interior water-air spray cooling contributes to significantly reducing the cycle time in the production of heat-treated tubes. This paper describes a new manufacturing method for prod...
