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The production of circular connectors must combine ecological sustainability with high productivity. Cold forging offers almost complete material utilization compared to currently used machining processes and significantly reduces the CO₂...

In bulk forming processes, the contact conditions are inhomogeneously distributed and change throughout the process, resulting in local variations of lubrication. However, current friction models assume constant lubricant behaviour, whereby...

To reduce friction and wear during the forming of aluminum sheet, tool surfaces made of a cast material (EN-GJS-700–2) were chemically oxidized and electrochemically phosphated. The phosphated coatings reduced the coefficient of friction by up to...

Particularly important for increasing the resource efficiency of technical components are not only lightweight design but also innovative manufacturing technologies, and process chains with closed material cycles. Using the example of a demonstrator...

Different material properties may induce slight deviations in surface condition, component temperature, and friction surface and thus significantly impair the bond of rotary friction welded steel-aluminium alloy joints. The effects of different...

Broaching is a key technology for manufacturing the safety-critical connection between turbine disk and blade. While offering, for instance, high process stability, geometric accuracy and productivity, these advantages are offset by high tool costs...

A process for analysing the manufacturability of stress-adapted components made of metal and fibre-reinforced hybrid structures using an industrial robot is being investigated. The use of an industrial robot makes it possible to circumvent previous...

Thin-walled precision components including bipolar and electrolyzer plates are key to the transformation towards sustainable energy usage and storage. Conventional forming technologies for these metallic components, however, are limited in...