Hendrik Gerland

Project engineer
Practice Areas:
process monitoring, bulk forming
+49 (0)511 279 76-344


Additive manufacturing makes it possible not only to attach RFID tags to identify components from the outside, but also to implement them directly in the component. Which processes are suitable – and to what extent can this process be automated?

Additive manufacturing, 3D printing, FDM, fused deposition modeling, identification, RFID

A new 3D printer in the research area for Additive Plastics Recycling at IPH can process plastic granulate. This allows components to be printed directly from recycled and shredded plastic or from injection molding material without first having to produce filament.

additive manufacturing, Plastics Recycling. 3D-Printing

Aluminum melting ovens have a very high energy consumption. Opening the oven doors for the visual monitoring of the melting preocess to be carried out by the operator increases the energy requirement and endangers occupational safety. To increase the energy efficiency of the oven, an optical measurement system was developed that monitors both the melting process and the condition of the melt pool. At the same time, the degree of automation was increased and occupational safety improved.

process optimization, energy efficiency, optical process monitoring

Multi-stage forging process chains are often used for the efficient production of complex geometries. Typically, these consist of homogeneous heating, one or more preform stages, and the final forging step. By inhomogeneously heated billets, the process chains can be simplified or shortened. This shall be achieved by setting various temperature fields within a billet, resulting in different yield stresses. These can influence the material flow, leading to easier production of complex parts. In this study, the influence of inhomogeneously heated billets on the forming process is investigated by means of FEA. For this purpose, two process chains including inhomogeneous heating and three homogeneously heated reference process chains are developed and compared. Each process chain is optimized until form filling and no defects occur. Target figures for the assessment are necessary forming force, the amount of material necessary to achieve form filling and die abrasion wear. For process chains with inhomogeneously heated billets, the results showed a small time window of about 5 s for a successful forming in terms of form filling. Forming forces and die abrasion wear increase for inhomogeneously heated billets due to higher initial flow stresses. However, the flash ratio decreases when billets are heated inhomogeneously. Depending on their size, inhomogeneously heated billets show up to 11.8% less flash than homogeneously heated billets. This shows a potential for the use of inhomogeneous heating to make forging processes more efficient. Subsequently, experimental tests will be carried out to verify the results of the simulations.

Inhomogeneous heating, Forging, FEA, Resource efficiency, Preform operation

Working on a real industrial project and getting professional practice in the process - students at Leibniz Universität Hannover have this opportunity in the "Cooperative Product Engineering" (KPE) project.

For more than 20 years, KPE has been offered as a semester project by Institut für Integrierte Produktion Hannover (IPH) gGmbH and Leibniz Universität Hannover. Students from the faculties of mechanical engineering and economics are given the opportunity here to apply their specialist knowledge from their studies in practice by working on a practical project for an industrial partner.


Student project

Research projects