The increasing demand for functional-integrated lightweight components is bringing established manufacturing technologies to their limits and motivates research into the innovative process class of sheet-bulk metal forming (SBMF). By applying bulk forming operations to sheet metal, thin-walled components with integrated functional elements can be produced in short process chains by a three dimensional material flow. Currently, pre-cut blanks are frequently used for this purpose. Manufacturing components from coil would combine the advantages of SBMF with those of production from coil regarding high output quantities. Therefore, the objective of the present research is to develop a fundamental process understanding for SBMF of parts from coil. For this purpose, a lateral and a backward extrusion process are set up and numerically mapped for a process analysis. Known challenges in SBMF of pre-cut blanks are a limited component accuracy due to a partly uncontrolled material flow and high tool loads. Consequently, both are addressed in context of a production from coil in a combined numerical-experimental approach. An anisotropic material flow is identified as a coil-specific challenge and fundamental difference to the SBMF of blanks. It causes an unequal forming of the components. The sheet geometry as well as a local pre-hardening induced by the forming of previous parts are found to determine the anisotropic material flow. In addition, an understanding of the effects of anisotropic material flow on tool loads is developed. An unequal deflection of tools is found as a tool-specific challenge. The obtained process knowledge provides a basis for research into measures to counteract the anisotropic material flow as a central challenge of SBMF of coils in future work.

对功能集成轻质组件的需求不断增加，这已使成熟的制造技术发挥到极致，并激发了对大块金属成形（SBMF）的创新工艺类别的研究。通过对钣金件进行批量成形操作，可以通过三维材料流以较短的工艺链生产具有集成功能元件的薄壁部件。当前，预切坯经常用于此目的。用卷材制造部件将结合SBMF的优势和用卷材生产的高产量。因此，本研究的目的是发展对卷材零件的SBMF的基本过程理解。以此目的，设置了横向和后向挤压工艺，并进行了数值映射，以进行工艺分析。预切割坯料的SBMF中的已知挑战是由于部分不受控制的物料流和高工具负荷而限制了部件精度。因此，在结合数值实验方法的卷材生产中解决了这两种问题。各向异性材料流被认为是线圈特定的挑战，并且是毛坯SBMF的根本区别。这会导致组件的成型不均。发现板材的几何形状以及由先前零件的形成引起的局部预硬化可以确定各向异性的材料流。此外，对各向异性材料流对工具载荷的影响的理解也得到了发展。发现工具不平等的偏斜是特定于工具的挑战。