Analysis and override of heat balance in sheet metal forming


In sheet metal forming of both aluminum and steel sheets we find heat from different sources to be developed. In consequence this can cause Aluminum-adhesion on forming tool surfaces. Strongly augmented process temperatures may lead to the collapse of the lubrication film in steel sheet forming. They also do require an active cooling of the forming tool to prevent any damage from overheating.


It is the aim of this project to establish a fundamental understanding for the different sources and sinks of heat balance in sheet metal forming. Thereby it is necessary to identify the main parameters of influence in order to develop practical guidelines as well as to derive cooling concepts for forming tools. The optimization of an active cooling of forming tools is essential under aspects of necessary heat flow volumes as well as the locating the most efficient position within a forming tool.


The first approach will be a fundamental experimental and numerical analysis of the different heat flows within the technical system. Heat can develop from dissipated forming energy (Qd), friction (Qr) and combined loading conditions. Within the next step it is planned to derive a thermal characteristic to fully describe the heat balance. Finally different concepts shall be designed which help to take an active influence on the temperatures and verified in a real forming tool.