Material forming and the role of measurement systems

What matters most in material forming in modern industrial facilities

Whether deep drawing, bending, forging, or rolling - industrial forming processes subject raw materials to extreme mechanical forces. During these processes, the microstructures of the material change in fractions of a second under immense stress.

For material testing during or immediately after the forming process to be successful, toolmakers and manufacturers must pay attention to the following key factors:

• Process stability and repeatability: Even with fluctuating raw material batches, the target geometries must be precisely maintained.
• Early defect detection: Without monitoring, dynamic overloads or microcracks lead to costly tool wear or scrap.
• Testing material limits: To produce components that are both lighter and more stable, forming processes often operate close to the material’s stress limit.

Why measurement devices must measure with extreme precision and speed

Standard measurement devices quickly reach their limits in highly dynamic forming processes. When tools strike the material within milliseconds, high-frequency pressure, force, and vibration signals are generated.

Seamless quality control and reliable crack detection therefore require measurement data acquisition systems with extremely high sampling rates and high resolution:

1. Reducing scrap: If measuring instruments fail to detect deviations, force spikes, or cracks in real time, defective material is processed further. Fast-responding systems stop or regulate the process before serial defects occur.
2. Transparent process development: When developing new forming technologies, highly dynamic data provides precise insights into material behavior. This significantly shortens development times.
3. Comprehensive documentation: For safety-critical industries, precise measurement data acquisition guarantees the traceability of every single forming operation.

Applications: Where material forming drives the industry

Material forming technology forms the backbone of numerous key industries. High-precision measurement systems are used in the following sectors, among others:

• Automotive industry: From complex body parts (e.g., high-strength sheet metal for the safety cell) to chassis components and high-stress parts for powertrains and electric motors.
• Aerospace: Forming of titanium and special alloys for engine and structural components under extreme quality assurance requirements.
• Electrical engineering & electronics: Micro-forming of contacts, connectors, and housing components in high volumes.
• Medical technology: Precision forming for implants and surgical instruments made of biocompatible materials.
• Heavy machinery and plant engineering: Drop forging and cold forming of large shafts, flanges, and connecting components.