C3: Alternative processes and materials for flexible tool elements

Field of work:

Integrated quality assurance and optimized processes and parts

In this research project, tool elements - including blankholder, punch and die - are produced out of alternative materials with the use of different RP processes. In reference tests, tools are indirectly produced out of zamak (sintered mold) as well as conventionally produced out of steel. Data on the quality of the blanks after deep drawing as well as on the condition of the tool is collected and subsequently compared against the number of pieces to be produced. The objective of this project is to determine the maximum number of pieces and to investigate the wear mechanisms for different combinations of the materials of tool and blank, which will result in failure of the tool. The dimensional accuracy and the surface roughness of the blanks and the dies are evaluated against the degree of wear which occurs on the tool and the number of pieces produced. An asymmetric rectangular geometry with different angles was chosen for the tests in order to compare the geometry-dependent wear on the tool with dimensional deviations of the blank. The use of different angles offers the determination of a correlation between maximum number of pieces at a defined degree of blank quality, of minimum radii and the sudden failure of the tools. The tests were carried out at the research institute utg using a follow-on composite tool which offers an output of up to 100,000 pieces in an appropriate period of time. Finally, it is possible to choose the most adequate tool material and thus the most adequate production process in order to assure a defined quality of the blanks against the number of pieces to be produced, the geometry and sheet material of the part.


Launching date




Funded by

Bavarian Research Foundation