SHIFT - Semi-Hot Integrated Forming für TRIP-unterstützte Stähle

Das primäre Ziel ist es, älteren Menschen ein sichereres und dennoch unabhängiges Leben in ihrer gewohnten oder betreuten Umgebung zu ermöglichen. Durch den Einsatz von Smart-Living-Technologien soll die Selbstständigkeit so lange wie möglich erhalten bleiben, während gleichzeitig das Sicherheitsgefühl der Bewohner gestärkt wird.

Ein zentrales wissenschaftliches Ziel ist die technologische Verbindung von Ambient Assisted Living (AAL) – also Sensoren im Wohnraum – mit medizinischen Vitaldaten (wie Herzfrequenz, Blutdruck oder Blutzucker). Die Forschung konzentriert sich darauf, wie diese unterschiedlichen Datenströme mittels KI sinnvoll zusammengeführt werden können, um ein ganzheitliches Bild des Gesundheitszustands zu erhalten.

Das Projekt verfolgt das Ziel, weg von einer rein reaktiven Behandlung hin zu einer proaktiven Prävention zu gelangen. Durch die kontinuierliche und komfortable Überwachung mittels medizinisch zertifizierter Geräte sollen kritische Veränderungen frühzeitig erkannt werden. Dies ermöglicht es, rechtzeitig medizinische Maßnahmen in der Prävention, Therapie oder Nachbehandlung einzuleiten und Folgeerkrankungen zu minimieren.

The process parameters of WP3 will be used to prepare the first trial runs of semi-hot forming on a lab-scale forming press. Depending on the required heating rates and temperatures, a suitable induction heating setup will be prepared. It is important to ensure homogeneous temperature within a certain pre-cut metal sheet.

Verification of correctly applying all relevant parameters is achieved by extracting samples from the semi-hot formed parts and comparing them to "ideally" treated samples based on the dilatometric tests.

Two generic geometries will be used: A simple U-shaped profile as well as a 3-dimensionally curved, complex part representing a generic car body structure part.

Based on the previous findings, the forming tools will be designed and manufactured, ensuring compliance with required process parameters. This will require temperature-controllable forming tools and respective cold forming tools for comparison.

Using the forming tools of WP5, try-out runs and manufacturing of the respective demonstrator parts are conducted. Especially the geometrical comparison between semi-hot and cold formed parts will show the achieved improvements regarding springback and geometric distortions. Finally, based on samples from the demonstrator parts, all properties will be verified: Mechanical testing to verify strength and ductility; Microstructure testing to ensure the retained austenite required for TRIP is still present; Coating/LME testing to verify the effectiveness of the integrated galvannealed coating.

Demonstrator parts of WP6 are checked for LME-induced cracking due to the forming process. Since the produced parts need to be spotwelded, a parameter study will be conducted to find optimal welding parameters and simultaneously determine how effective the GA coating is against LME. Additional corrosion resistance testing will conclude this workpackage.

Using semi-hot formed samples, all necessary parameters for detailed FE-simulation are determined. The simulation is focused on crashworthiness, which is accompanied by parallel real-world testing of the demonstrator parts. This allows for detailed assessment of their deformation behavior and crashworthiness.

Finally, based on the developed process route and achievable improvements, ecological and economic implications of implementing this process in car parts production will be assessed.