Metal Forming Technology and Laser Material Processing Laboratory (UTL)

Tasks

Laboratory for metal forming and laser material processing with various laboratory equipment

In the Metal Forming Technology and Laser Material Processing Laboratory, practical experiments to accompany the lectures on production engineering, metal forming and laser material processing are carried out in the form of laboratory exercises, project work is supported, and Bachelor and Master theses are supervised.

The tasks are supported with simulations and cover the whole process chain from the design of shaped sheet metal parts via the production through to the jointing.

Sheet metal forming: deep-drawing, bending, stretch forming, tribology, cutting
Bulk deformation impact extrusion, compression, rolling
Laser material processing: laser cutting, welding, marking
Press technology: structure, press drives
Tool engineering: method development, design, prototype dies

Staff

Prof. Dr.-Ing. Stefan Wagner
Hochschule Esslingen
Fakultät Maschinen und Systeme
Labor für Umformtechnik und Lasermaterialbearbeitung
Kanalstraße 33
73728 Esslingen am Neckar

Telefon: +49 (0)711-397-3586
Telefax: +49 (0)711-397-48 3586

weitere Ansprechpartner

Laboringenieur: Dipl.-Ing. (FH) Achim Herdtle

Equipment

A single-connecting rod automatic punching press of the model CSP 100 can be seen

CSP 100 Single connecting rod stamping press

Presses

Servo press (CSP 100 automatic stamping press)
F = 1,000 kN, see photo
Hydraulic triple effect deep-drawing press
F = 1,000 kN
Hydraulic double effect deep-drawing press
F = 630 kN
Eccentric press F = 630 kN

You can see a robot in orange for roll hemming

Robot for roll hemming

Testing equipment

TruBend 7036 bending machine
Acquisition Forming Limit Curve FLC (under construction)
Roll hemming machine with Kuka robot, see photo
Strip drawing facility
Experimental roll stand

Deformability behaviour of sheet metals

- Recording Forming Limit Curve, see figure

Laser system

Laser systems

True LaserCell 3000 4 kW disc laser, see photo

TrueMark Station 5000 marking laser

Workshop equipment

Machine tools for toolmaking
Equipment to produce prototype dies from low melting-point metal alloys
Metrological equipment to measure and record forming processes

Laboratory exercises

Execution of bending tests by a student in the laboratory

Carrying out bending experiments

1. Semester

Foundations of forming technology
Strain hardening
Deep-drawing, bending, cutting, impact extrusion

Simulation of a deep drawing process with AutoForm on a computer

Simulation of a deep-drawing process using AutoForm

Lectures within the scope of the application module are partly held at the Trumpf company in Ditzingen in a room

Some lectures in the practical application module take place at Trumpf in Ditzingen

Laboratory exercises within the framework of the application module are partly carried out at the Trumpf company in Ditzingen

Some laboratory exercises in the practical application module take place at Trumpf in Ditzingen

6. Semester (Practical application module metal forming/laser machining):

Simulation with AutoForm: Tutorials developed at Esslingen University of Applied Sciences to accompany the lectures on metal forming help you to learn how to operate the AutoForm FE program using concrete, real-life applications.
Rapid Prototyping: You develop the optimum size of the starting blank for a deep-drawn part. Every student produces a drawn part with the aid of a prototype tool cast from a low-melting point zinc alloy.
Press drives: Different press drives are compared in the Metal Forming Laboratory.
Laser technology: Learn how a laser can be used for machining materials.
Programming of laser cutting and bending systems: At Trumpf (Ditzingen), you will develop a 3D shaped sheet metal part and program the laser cutting and bending machine for this part. The component you have developed will then be fabricated.

The graphic shows the drive module of the automatic servo-punching press

Drive module of the automatic servo die-cutting press

Master RMM:

Efficient drives for metal forming presses: You gain direct experience of the advantages of the direct drive with a modern mechanical press with servo-drive.
Method development: With the aid of concrete case studies, you develop the process chains to produce shaped sheet metal parts. You use the AutoForm FE system to support you.

Research and knowledge transfer

Research activities

The Metal Forming and Machining of Lasermaterial Laboratory headed by Prof. Dr. Wagner collaborates closely with industrial companies in Baden-Württemberg. Medium-sized and small companies are often looking for support with process engineering issues. They in particular require simple and low-cost solutions.