Simulative basic investigation for a new forming process punch-hole-rolling

Future products will require new forming processes in order to meet the increasing requirements for innovative products. These processes will enable new possibilities in product manufacturing and the control of product properties beyond geometry control. For this purpose, a new process called punch-hole-rolling has been developed, which enables the production of a double-sided collar in thin sheet structures. Punch-hole-rolling is a two-stage process combination of conventional shear cutting and novel rolling which is carried out in one tool. The process combination allows to derive product data from the punching process for the control of the flexible hole-rolling in order to control product properties such as geometry, hardness and microstructure. In order to increase the process understanding and classification, an FE-simulation is built and validated by experiments.