ISBN 978-3-88355-390-0 Papers of the International Conference on “New Developments in Sheet Metal Forming” in Fellbach (near Stuttgart) - Germany, held on May 22nd-23rd, 2012. Conference Chairman: Prof. Dr.-Ing. Mathias Liewald MBA Director of the Institute for Metal Forming Technology (IFU) of University of Stuttgart in cooperation with: The “Forschungsgesellschaft Umformtechnik mbH“ (FGU, Stuttgart - Germany), and the “Deutsche Gesellschaft für Materialkunde e.V.” (DGM, Frankfurt - Germany) All contributions to these conference proceedings are published as written by indicated authors. Contents and orthography of contribution belong into scope of responsibility of respective author / authors. © 2012 MAT INFO Werkstoff-Informationsgesellschaft mbH Hamburger Allee 26, 60486 Frankfurt am Main - Germany All rights reserved Printed in Germany

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Preface The International Conference “New Developments in Sheet Metal Forming Technology” in Stuttgart / Germany is held every second year alternating with the International Conference “New Developments in Forging Technology”. Main goal of both conferences is to join engineers and specialists from industry and scientists from universities for a dispute in technology regarding analysis of state of the art in metal forming, tendencies and future targets in research and development of new sheet metal and/or bulk metal forming technologies respectively. The organizer (Institute for Metal Forming Technology (IFU/ Stuttgart/ Germany) annually arranges this venue together with Forschungsgesellschaft Umformtechnik mbH (FGU/ Stuttgart/ Germany). Additional goal of the conference since many years includes the transfer of scientific results into value added chains and particular markets of today. Presented topics of selected papers of conference for this reason must be evaluated in context to current explicit research activities in sheet metal forming in Europe, United States and Asia. Finally the conference and its contributions also intend to present strategic issues of sheet metal production technology to external specialists and to figure out present state of the art. Within scope of this two days conference, experts from both universities and industrial companies will present papers. Presented topics should encompass the investigations at several European metal forming institutes, companies from industry and the Institute for Metal Forming Technology (IFU) of University of Stuttgart for discussing new results with experts from all over the world. Thus, an adequate mix of practical and theoretical contributions and papers will be provided. Key note of this conference held on May 22nd-23rd, 2012 is entitled: “Customers Future Products – Impact on Own Manufacturing Processes, Sites and Production Organisation” and will focus strongly on entire range of impacting factors due to changes in customer markets on supplying companies value chains, globalization strategy and internal manufacturing process organization. For that reason conference agenda right at the beginning contains strategic papers from managerial point of view. Recent volatile developments of today's markets mainly attract company´s attention in terms of analysis of emerging

VI market trends and finding suitable solutions of novel internal manufacturing processes or modified value chains by networking together with partners. Also differentiated management of new products to be launched in sites and subsidiaries or eruptive changes by innovation in organization may keep companies on the cutting edge. Presented papers and the panel discussion held on the second conference day may provide to attendees achieved milestones of today, solutions and future perspectives. After this discussion attendees will be given the opportunity to participate in this dispute, to comment on recognized market trends in sheet metal forming or to contribute in particular. Achieved results of the panel discussion are not considered in this book. I would like to thank all authors for contributing and participants of the panel discussion on the second conference day for their effort in particular. My thanks also goes to the Deutsche Gesellschaft für Materialkunde e.V. (DGM), Frankfurt/Main, Germany, who will attach these proceedings to its publishing program. I am sure, this book comprising papers presented on May 22nd-23rd, 2012 will be dispatched widely and will be available to experts involved.

Sincerely yours Prof. Dr.-Ing. Mathias Liewald MBA

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Table of Contents Preface / Introduction

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M. Liewald Plenary Lectures Resource Gentle Light Weight Construction for Today’s and Oncoming Mobility H. Ferkel, O. Hoffmann, L. Keßler Japanese Machine Tool Industry in 2012 and AIDA ENGINEERING

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Position in the Global Market K. Aida Flexibility, Productivity, and Innovation Power – Core Competencies of a

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Tier 1 Supplier P. Dahlke Production and Lightweight Design Multimaterial Lightweight Design – A Challenge for Development and Production

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K.-H. Füller The Future of Lightweight Manufacturing - Production-related Challenges

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when Hybridizing Metals and Continuous Fiber-reinforced Plastics J. Fleischer, A. Ochs, S. Dosch Does Steel have a Future in Automotive Car Body Design?

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K. Berenz, M. Rupp Innovation and Globalization as a Factor of Success for Global Hotstamping Growth B. Osburg, G. Lengfeld, O. Straube

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VIII Press Hardening Die Design and Process Developments for Press-hardening of Zinc Coated Steel

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R. Kelsch, A. Sommer, T. Kurz, M. Rosner Development of Laser Cladded Tool Surfaces for Press Hardening Processes

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R. Kolleck, R. Vollmer, C. Koroschetz Tool Engineering Development of Bionic Design Approaches to Metal Forming Tools

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E. Oswald, M. Liewald, J. Spindler, O. Stephan Prediction of the Surface Quality of Deep Drawn Parts in the Automotive

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Industry by the Virtual Yoshida Buckling Test (abbreviated YBT) N. Koch, M. Liewald, F. Bäcker System Controlled Process Planning to Support Planning Processes in the

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Technology Forming M. Ganser, Ö. Dirim, S. Rudolph, S. Huhn Sheet Materials A European Round Robin Test for the Hole Expansion Test According to

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ISO 16630 E. Atzema, M. Borsutzki, M. Braun, S. Brockmann, M. Bülter, B. Carlsson, P. Larour, A. Richter Steel: The Innovative Lightweight Material

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E. Arenholz Relevance of the Production Chain for Material Characteristics and Surface Quality of Al Automotive Sheet K. F. Karhausen, H. Aretz, G. Nitzsche

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IX Advances in Metal Forming Limits Under Nonlinear and Out-of-Plane

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Forming Conditions T. B. Stoughton, J.-W. Yoon Current Research Work into Sheet Metal Forming at the Institute for

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Metal Forming Technology (IFU) at the University of Stuttgart M. Liewald, S. Wagner Productivity and Quality Increase in the Press Shop by Means of a Robustness

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Simulation during the Engineering Phase A. Emrich, G. Ruf, M. Liewald, D. Lorenz Machines and Equipment The Development of Machine Tools between International Requirements and

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Technological Trends W. Erlenmaier, J. Kappes The New Servo Press Generation for the Automotive Industry

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W. Wiedenmann Servo Technology and Energy Management of Servo Presses – Status and Trends

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K. Rothenhagen Simulation Virtual Prototyping with Focus Body in White and Chassis Manufacturing in

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Automotive Industry E. Retraint, H. Porzner, M. Skrikerud Parametric Process Chain Simulation – From Metal Forming to Lifetime Simulation 347 T. Menke, S. Pinner, G. Scheuerer Virtual Product- and Process Validation – The Paint Drying Process C. Albiez, M. Liewald, G. Meyer, O. Schmidl, A. Görres

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X Water-based Synthetic Lubricants for Metal Forming A. Losch, M. Jahn, K. Borst, P. Bosler Jr., B. Hendershott

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