Self-adapting systems in forming technology

Abstract This review examines how self-adapting principles can be transferred to metal forming technology. It defines self-adapting forming systems as systems that improve process performance through intrinsic physical adaptation mechanisms rather than externally imposed control. Based on concepts from self-engineering systems and soft robotics, a taxonomy is derived that distinguishes adaptation according to system level, energy supply, actuation principle and location of the adaptive effect. Representative examples from bulk and sheet metal forming are analysed, including spring-attached dies in forging, floating dies in bending, adaptive flash gaps in closed-die forging, and self-adjusting blank holder concepts in deep drawing. The reviewed examples indicate that physically embedded adaptation mechanisms can contribute to improved robustness, reduced forming loads and lower control complexity in selected forming processes. Finally, prospective concepts such as smart materials, programmable lubricants and mechanically self-adjusting tool systems are discussed as potential routes for future self-adapting forming systems.