digiMass – Development of a closed digital process chain from forming to strength assessment for massive forming

BMWE KTF-Project / Project start /

In computer-aided design, the dimensioning of a component is generally based on load assumptions, available installation space, and the static material properties. Furthermore, chassis components are subjected to high cyclic loads during operation, and their damaging effects must be considered. For weight-saving reasons, the components’ basic structure is often forged from wrought aluminum alloys.

Forging and the subsequent manufacturing steps influence the component’s fatigue strength. While significant localized deformation occurs during forming, the fatigue strength assessment must account for small, recurring deformations, with the load-bearing capacity in service depending on the local deformation history resulting from the forming process. In the case of formed wrought aluminum alloys, heat treatment is carried out following forming to establish a defined temper. The result of the heat treatment depends, among other things, on the local stress state and the grain orientation, i.e., the deformation history.

The aim of the digiMass project is to establish a digital process chain, from bulk forming to structural integrity assessment using deformation history, in such a way that it can be utilized based on existing simulation and analysis tools, thereby promoting energy-efficient component design. This approach integrates material requirements, manufacturing, and component functionality into a single optimization loop. Coupled modeling enables a simulation-based determination of the local structural integrity of components, which was previously not possible. This allows components to be designed with significantly lower safety margins, thereby harnessing the aluminum’s high lightweight construction potential to conserve resources.

Consortium

  • Fraunhofer LBF
  • Fraunhofer IWU
  • Fraunhofer SCAI
  • LEIBER Group GmbH & Co. KG
  • ZF Friedrichshafen AG

Associated Partners

  • Hottinger, Brüel & Kjaer GmbH,
  • Maxion Wheels Holding GmbH,
  • Seidel Werkzeugbau GmbH,
  • Simufact Engineering GmbH,
  • Transvalor S.A.,
  • Wilhelm Alte GmbH

The project is funded through the Climate and Transformation Fund of the Federal Ministry for Economic Affairs and Energy (BMWE).

Project duration: 03/2026 to 02/2029