Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik (IWU)

Offer

The Fraunhofer Institute for Machine Tools and Forming Technology IWU is one of the world’s most important research and development
establishments in the field of manufacturing science. Our highly qualified staff based in Chemnitz, Dresden and Augsburg conduct research in the core competencies of adaptronics, mechatronics, machine tools, forming technology, joining and assembly technology and virtual reality.

A main focus of our work includes the development of intelligent production systems and the optimization of forming and cutting manufacturing processes.

We create innovative solutions for continuous process chains, from the components to the assembly units, all the way up to complex machine systems and completely new kinematics. Lightweight structures and the use of new materials, which are also applied in the aerospace sector, are playing a great role in our research work.

Our range of services for the aerospace sector comprises for example:
* massive and sheet metal forming of highperformance materials for the aircraft engine area
* technologies and equipment for the machining of engine elements
* innovative mechanical joining techniques
* the development of intelligent components – for example for positioning systems of helicopters

Since its founding, the Institute has undergone continual growth and improvements in both its administrative and research facilities. These efforts were crowned by the new test facilities which were opened at an official ceremony. The facilities consist of a shop for forming technology with machine tools for sheet and bulk metal forming, a shop for tool manufacturing with precision machine tools, 3D-coordinate measuring technique and machining centres for cutting methods, as well as a laboratory and office area. The Institute is laid out over 6,000 m², where research for regional, national and international machine and automotive industry can be conducted.

Research focus:

- Process chains: development of processing methods for tool and die making as well as for drive train components; design and planning of methods for sheet metal and solid forming as well as hydroforming; simulation of processes and procedures

- Cutting processing methods: milling (3- and 5-axis, Parallel Kinematics Machines); ultrasonic and laser-assisted machining; fine surface processing (polishing, smoothing, rolling); drilling, milling

- Forming technology: methods for sheet metal forming, also for special materials; hydroforming of tubes, profiles and blanks including tool technology; cold and warm solid metal forming (extrusion, profile rolling, spin extrusion); hot solid metal forming (cross rolling, axial die rolling, forging); joining by forming; tool and die construction

- EDM, ECM

- Manufacturing and processing of metal foams

- Process combination

One focus of the Fraunhofer IWU is energy and resource efficiency.
As energy cost is constantly increasing, manufacturing companies are required to continuously optimize the production factor energy as well as its supply, distribution, utilization and storage. Thus, waste of energy has to be detected and eliminated, considering process, plants, infrastructure and buildings. The energy consumption of manufacturing companies can be optimized based on analyses of energy efficiency. For example, solutions were developed at the Fraunhofer IWU for energy recovery in gas reduction systems. Additional energy storage systems enable more efficient control of energy requirements in machine tools. Experience shows that standardized solutions are not possible for energy optimization of manufacturing companies. The main prerequisites are too complex for the technological equipment of buildings and for production plants. These prerequisites include the industrial sector, company size, type of manufacturing and state-of-the-art.

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