Cold Micro Metal Forming: Research Report of The Collaborative Research Center "Micro Cold Forming" (SFB 747), Bremen, Germany Frank Vollertsen

Cold Micro Metal Forming: Research
Report of the Collaborative Research

Center “Micro Cold Forming” (SFB 747),
Bremen, Germany Frank Vollertsen
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Lecture Notes in Production Engineering
Frank Vollertsen
Sybille Friedrich
Bernd Kuhfuß
Peter Maaß
Claus Thomy
Hans-Werner Zoch Editors
Cold Micro
Metal Forming
Research Report of the Collaborative
Research Center “Micro Cold Forming”
(SFB 747), Bremen, Germany
Lecture Notes in Production Engineering (LNPE) is a new book series that
reports the latest research and developments in Production Engineering, comprising:
• Biomanufacturing
• Control and Management of Processes
• Cutting and Forming
• Design
• Life Cycle Engineering
• Machines and Systems
• Optimization
• Precision Engineering and Metrology
• Surfaces
LNPE publishes authored conference proceedings, contributed volumes and

authored monographs that present cutting-edge research information as well as
new perspectives on classical fields, while maintaining Springer’s high standards of
excellence. Also considered for publication are lecture notes and other related
material of exceptionally high quality and interest. The subject matter should be
original and timely, reporting the latest research and developments in all areas of
production engineering.
The target audience of LNPE consists of advanced level students, researchers, as
well as industry professionals working at the forefront of their fields. Much
like Springer’s other Lecture Notes series, LNPE will be distributed through
Springer’s print and electronic publishing channels. To submit a proposal or
request further information please contact Anthony Doyle, Publishing Editor
(jan-philip.schmidt@springer.com).
More information about this series at http://www.springer.com/series/10642

Frank Vollertsen Sybille Friedrich
• •
Bernd Kuhfuß Peter Maaß

• •
Claus Thomy Hans-Werner Zoch

•
Editors
Cold Micro Metal Forming

Research Report of the Collaborative
Research Center “Micro Cold Forming”
(SFB 747), Bremen, Germany
Final report of the DFG Collaborative Research
Center 747
Editors
Frank Vollertsen Sybille Friedrich
BIAS—Bremer Institut für angewandte BIAS—Bremer Institut für angewandte
Strahltechnik GmbH Strahltechnik GmbH
Bremen, Germany Bremen, Germany
Bernd Kuhfuß Peter Maaß

Fachbereich Produktionstechnik Zentrum für Technomathematik
Universität Bremen Universität Bremen
Claus Thomy Hans-Werner Zoch

BIAS—Bremer Institut für angewandte Stiftung Institut für Werkstofftechnik
Strahltechnik GmbH IWT
ISSN 2194-0525 ISSN 2194-0533 (electronic)

ISBN 978-3-030-11279-0 ISBN 978-3-030-11280-6 (eBook)
https://doi.org/10.1007/978-3-030-11280-6
Library of Congress Control Number: 2018967417
© The Editor(s) (if applicable) and The Author(s) 2020. This book is an open access publication.
Open Access This book is licensed under the terms of the Creative Commons Attribution 4.0
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Preface
This book gives an overview of the main research results, which are valuable to
enable a stable and understood mass production with lot sizes of more than
1,000,000 metal parts by micro forming. The results have been gained in the years
2007 to 2018 within the framework of the German Collaborative Research Center
(CRC) “Micro Cold Forming—Processes, Characterization, Optimization” (SFB
747 “Mikrokaltumformen—Prozesse, Charakterisierung, Optimierung”) of the
University of Bremen.
Chapter 1 of this book covers the motivation for the research on a reliable
production as well as information about the structure and the partners within the
collaboration and gives an overview of the main results, which were gained for
mastering effects occurring in mass production. Besides processes and methods for
improving the forming processes itself, also the mastering of the complete pro-
duction line and the aspect of high flexibility in the design of processes and pro-
duction systems are addressed. Within this overarching description, references for
more detailed information in the following chapters are given.
Each of Chaps. 2–6 focuses on a field of competence covered by the CRC.
Fields of competence are micro forming, process design, tooling, quality control
and characterization as well as materials, especially designed for micro forming.
Within this frame, all subprojects of the third funding period present their results in
Sects 2.1–6.4 in more detail, and each subproject is giving answers to a special
aspect, which allows mastering mass production of micro parts. The interdisci-
plinary cooperation between the researchers from production engineering, mathe-
matics and physics, who are working in several institutes, is an excellent base for
research in the demanding field of micro metal forming.
All the editors of this contributed book are the members of the executive board
of the CRC. Head of the board and of the CRC is Frank Vollertsen. All the authors,
who contributed to this book, work in the relevant fields of the CRC. They are
directors or staff members of the collaborating research institutes. This book
extends the knowledge presented in the more fundamental book “Micro Metal
Forming” (Ed. F. Vollertsen, published by Springer).
v
vi Preface
A prerequisite for successful cooperation is the funding of manpower and

equipment, which was granted by Deutsche Forschungsgemeinschaft (DFG) and
the University of Bremen. We gratefully acknowledge this support. The editors
appreciate the powerful collaborations of the researchers within the CRC, which
have been the key for the successful work.
On behalf of the editors
Bremen, Germany Frank Vollertsen

November 2018 Head of the CRC (SFB 747 Mikrokaltumformen)
Acknowledgements The editors and authors of this book like to thank the Deutsche
Forschungsgemeinschaft (DFG), German Research Foundation, for the financial support of the
SFB 747 “Mikrokaltumformen—Prozesse, Charakerisierung, Optimierung” (Collaborative
Research Center “Micro Cold Forming—Processes, Characterization, Optimization”). We also like
to thank our members and project partners of the industrial working group as well as our inter-
national research partners, for their successful cooperation.
Contents
1 Introduction to Collaborative Research Center Micro Cold

Forming (SFB 747) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Frank Vollertsen, Sybille Friedrich, Claus Thomy,
Ann-Kathrin Onken, Kirsten Tracht, Florian Böhmermann,
Oltmann Riemer, Andreas Fischer and Ralf B. Bergmann
2 Micro Forming Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bernd Kuhfuss, Christine Schattmann, Mischa Jahn, Alfred Schmidt,
Frank Vollertsen, Eric Moumi, Christian Schenck, Marius Herrmann,
Svetlana Ishkina, Lewin Rathmann and Lukas Heinrich
3 Process Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Claus Thomy, Philipp Wilhelmi, Ann-Kathrin Onken,
Christian Schenck, Bernd Kuhfuss, Kirsten Tracht, Daniel Rippel,
Michael Lütjen and Michael Freitag
4 Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Frank Vollertsen, Joseph Seven, Hamza Messaoudi,
Merlin Mikulewitsch, Andreas Fischer, Gert Goch, Salar Mehrafsun,
Oltmann Riemer, Peter Maaß, Florian Böhmermann,
Iwona Piotrowska-Kurczewski, Phil Gralla, Frederik Elsner-Dörge,
Jost Vehmeyer, Melanie Willert, Axel Meier, Igor Zahn,
Ekkard Brinksmeier and Christian Robert
5 Quality Control and Characterization . . . . . . . . . . . . . . . . . . . . . . . 253
Peter Maaß, Iwona Piotrowska-Kurczewski, Mostafa Agour,
Axel von Freyberg, Benjamin Staar, Claas Falldorf, Andreas Fischer,
Michael Lütjen, Michael Freitag, Gert Goch, Ralf B. Bergmann,
Aleksandar Simic, Merlin Mikulewitsch, Bernd Köhler,
Brigitte Clausen and Hans-Werner Zoch
vii
viii Contents
6 Materials for Micro Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Hans-Werner Zoch, Alwin Schulz, Chengsong Cui, Andreas Mehner,
Julien Kovac, Anastasiya Toenjes and Axel von Hehl
Contributors
Mostafa Agour BIAS—Bremer Institut für angewandte Strahltechnik GmbH,

Bremen, Germany;
Faculty of Science, Department of Physics, Aswan University, Aswan, Egypt
Ralf B. Bergmann BIAS—Bremer Institut für angewandte Strahltechnik GmbH,
University of Bremen, Bremen, Germany;
Physics and Electrical Engineering and MAPEX Center for Materials and
Processes, University of Bremen, Bremen, Germany
Florian Böhmermann Laboratory for Precision Machining—LFM, Leibniz
Institute for Materials Engineering—IWT, Bremen, Germany;
Leibniz-Institut für Werkstofforientierte Technologien—IWT, University of
Bremen, Bremen, Germany
Ekkard Brinksmeier LFM Laboratory for Precision Machining, Leibniz-Institut
fur Werkstofforientierte Technologien—IWT, Bremen, Germany
Brigitte Clausen Leibniz-Institut für Werkstofforientierte Technologien, Bremen,
Germany
Chengsong Cui Leibniz Institute for Materials Engineering—IWT, University of
Frederik Elsner-Dörge Labor für Mikrozerspanung—LFM, Leibniz Institute for
Materials Engineering—IWT, Bremen, Germany
Claas Falldorf BIAS—Bremer Institut für angewandte Strahltechnik GmbH,
Bremen, Germany
Andreas Fischer BIMAQ—Bremen Institute for Metrology, Automation and
Quality Science, University of Bremen, Bremen, Germany
Michael Freitag Faculty of Production Engineering, University of Bremen,
Bremen, Germany;
BIBA—Bremer Institut für Produktion und Logistik GmbH, Bremen, Germany
ix
x Contributors
Sybille Friedrich BIAS—Bremer Institut für angewandte Strahltechnik GmbH,

University of Bremen, Bremen, Germany
Gert Goch BIMAQ—Bremen Institute for Metrology, Automation and Quality
Science, University of Bremen, Bremen, Germany;
The University of North Carolina at Charlotte, Charlotte, USA
Phil Gralla Center for Industrial Mathematics, University of Bremen, Bremen,
Germany
Lukas Heinrich BIAS—Bremer Institut für angewandte Strahltechnik GmbH,
Bremen, Germany
Marius Herrmann Bremen Institute for Mechanical Engineering (bime), Bremen,
Germany
Svetlana Ishkina Bremen Institute for Mechanical Engineering (bime), Bremen,
Germany
Mischa Jahn Zentrum für Technomathematik, Bremen, Germany
Bernd Köhler Leibniz-Institut für Werkstofforientierte Technologien, Bremen,
Germany
Julien Kovac Leibniz Institute for Materials Engineering—IWT, University of
Bernd Kuhfuss Bremen Institute for Mechanical Engineering (bime), University
of Bremen, Bremen, Germany
Michael Lütjen BIBA—Bremer Institut für Produktion und Logistik GmbH,
Peter Maaß Zentrum für Technomathematik, Bremen, Germany;
Center for Industrial Mathematics, University of Bremen, Bremen, Germany
Andreas Mehner Leibniz Institute for Materials Engineering—IWT, University
Salar Mehrafsun BIAS—Bremer Institut für angewandte Strahltechnik GmbH,
Bremen, Germany
Axel Meier Labor für Mikrozerspanung—LFM, Leibniz Institute for Materials
Engineering—IWT, Bremen, Germany
Hamza Messaoudi BIAS—Bremer Institut für angewandte Strahltechnik GmbH,
Bremen, Germany
Merlin Mikulewitsch BIMAQ—Bremen Institute for Metrology, Automation and
Eric Moumi Bremen Institute for Mechanical Engineering (bime), Bremen,
Germany
Contributors xi
Ann-Kathrin Onken Bremen Institute for Mechanical Engineering (bime),

Iwona Piotrowska-Kurczewski Zentrum für Technomathematik, Bremen,
Germany;
Center for Industrial Mathematics, University of Bremen, Bremen, Germany
Lewin Rathmann BIAS—Bremer Institut für angewandte Strahltechnik GmbH,
Bremen, Germany
Oltmann Riemer Leibniz-Institut für Werkstofforientierte Technologien—IWT,
University of Bremen, Bremen, Germany;
Laboratory for Precision Machining—LFM, Leibniz Institute for Materials
Daniel Rippel BIBA—Bremer Institut für Produktion und Logistik GmbH,
Christian Robert LFM Laboratory for Precision Machining, Leibniz-Institut für
Werkstofforientierte Technologien—IWT, University of Bremen, Bremen,
Germany
Christine Schattmann BIAS—Bremer Institut für angewandte Strahltechnik
GmbH, Bremen, Germany
Christian Schenck Bremen Institute for Mechanical Engineering (bime),
Alfred Schmidt Zentrum für Technomathematik, Bremen, Germany
Alwin Schulz Leibniz Institute for Materials Engineering—IWT, University of
Joseph Seven BIAS—Bremer Institut für angewandte Strahltechnik GmbH,
Bremen, Germany
Aleksandar Simic BIAS—Bremer Institut für angewandte Strahltechnik GmbH,
Bremen, Germany
Benjamin Staar BIBA—Bremer Institut für Produktion und Logistik GmbH,
Bremen, Germany
Claus Thomy BIAS—Bremer Institut für Angewandte Strahltechnik GmbH,
Anastasiya Toenjes Leibniz Institute for Materials Engineering—IWT, University
Kirsten Tracht Bremen Institute for Mechanical Engineering (bime), University
Jost Vehmeyer Center for Industrial Mathematics, University of Bremen, Bremen,
Germany
xii Contributors
Frank Vollertsen Faculty of Production Engineering-Production Engineering

GmbH, University of Bremen, Bremen, Germany;
BIAS—Bremer Institut für angewandte Strahltechnik GmbH, University of
Axel von Freyberg BIMAQ—Bremen Institute for Metrology, Automation and
Axel von Hehl Leibniz Institute for Materials Engineering—IWT, University of
Philipp Wilhelmi Bremen Institute for Mechanical Engineering (bime), University
Melanie Willert Leibniz-Institut für Werkstofforientierte Technologien—IWT,
Igor Zahn Bremer Goldschlaegerei (BEGO), Bremen, Germany
Hans-Werner Zoch Leibniz Institute for Materials Engineering—IWT,
Chapter 1
Introduction to Collaborative Research
Center Micro Cold Forming (SFB 747)
Frank Vollertsen, Sybille Friedrich, Claus Thomy,

Ann-Kathrin Onken, Kirsten Tracht, Florian Böhmermann,
Oltmann Riemer, Andreas Fischer and Ralf B. Bergmann
1.1 Motivation
Frank Vollertsen*, Sybille Friedrich and Claus Thomy

Micro systems technology is one of the key enabling technologies of the 21st century
[Hes03], with increasing relevance due to a general trend towards miniaturisation in
many industries. The main boosters for this trend are currently the consumer and
communication electronics market and—to a lesser extent—medical technology
(especially microfluidic devices, which had a market volume of approx. $2.5B in 2017
[Cle17]). As an example, for the companies organized in the industry association
F. Vollertsen (&) S. Friedrich C. Thomy R. B. Bergmann (&)

BIAS—Bremer Institut für angewandte Strahltechnik GmbH, University of Bremen,
Bremen, Germany
e-mail: info-mbs@bias.de
R. B. Bergmann
e-mail: Bergmann@bias.de
A.-K. Onken K. Tracht (&)
e-mail: tracht@bime.de
F. Böhmermann (&) O. Riemer (&)
Laboratory for Precision Machining—LFM, Leibniz Institute for Materials
e-mail: boehmermann@iwt.uni-bremen.de
O. Riemer
e-mail: riemer@iwt.uni-bremen.de
A. Fischer (&)
BIMAQ—Bremen Institute for Metrology, Automation and Quality Science,
e-mail: andreas.fischer@bimaq.de
© The Author(s) 2020 1

F. Vollertsen et al. (eds.), Cold Micro Metal Forming, Lecture Notes
in Production Engineering, https://doi.org/10.1007/978-3-030-11280-6_1
2 F. Vollertsen et al.
IVAM Microtechnology Network, medical technology is by far the most important

market [NN14]. Nevertheless, in the context of electromobility, autonomous driving,
and industry 4.0, there should also be a significant increase in the demand for existing
MEMS (micro electromechanical systems) including connectors, as well as a need for
further improvement, miniaturization and functional integration.
A typical example of the benefits and challenges of miniaturization is the ABS
(anti-blocking system) in modern cars. Whilst the weight could be decreased to
approx. 10% of the weight of the first system, the part complexity has significantly
increased. This is indicated by the decrease in the number of parts by approx. 90%
in current systems, compared to the first versions [Nos14], even though additional
functions are integrated. The trend towards an increase in miniaturization can also
be illustrated using the example of HF (high frequency) connectors, where nowa-
days the minimum pin diameters commercially available off the shelf are in the
range of 0.7 mm, with allowable tolerances for functional features of several µm.
As in most of the applications discussed above, significant quantities of parts
ranging from several thousands to literally billions (e.g. for resistor end caps) have
to be produced, micro cold forming is among the dominant production processes.
Examples of components (containing) micro parts produced by cold forming are
(listed by their application areas):
Medical technology/chemical technology: Hearing aid devices, cardiac pacemakers,
micro pumps and micro pump couplings, microfluidic reactor devices;
Automotive technology: ABS and other advanced assistance systems based on
MEMS, contacts and connectors, fuel pumps, injection nozzles;
Electronics: Battery caps, displays, diodes, electrodes, connectors, resistors, noz-
zles, contactors;
General industry: sensors (e.g. for pressure), hydraulic and pneumatic connectors,
micro pumps, micro valves;
Consumer electronics: smartphone speakers, electric blades, compact cameras,
microphones.
As a first conclusion, we find three main trends: an increase in miniaturization,
an increase in functional integration, and an increase in total batch sizes. Moreover,
common to many of these applications is the need for zero-defect quality. This is
often due not only to cost considerations, but also to the safety criticality of many of
the components (ABS, medical devices).
Consequently, and as most micro forming parts are produced under extreme cost
pressure, the complete process chain has to be optimized to enable further
cost-efficient miniaturization. This means that not only aspects relating to the micro
cold forming process as such (e.g. non-systematic scatter in material properties), but
also preceding and succeeding process steps (e.g. heat treatment) as well as
materials handling have to be considered and optimized along the process chain.
Moreover, in order to increase process stability and part quality, novel tool mate-
rials and tool production processes have to be investigated to minimize tolerances
and improve wear behavior. Finally, and this is among the most urgent industrial
needs in view of zero-defect requirements, methods and systems for 100% inline
measurement and inspection at production rates of from 60 to 300/min and more are
1 Introduction to Collaborative Research … 3
required (depending, of course, on the part complexity). This is especially true for
systems allowing the optical inspection and measurement of complex features,
which are often inside longer cavities.
Research on micro metal forming in Germany was developed by Engel and
Geiger, starting in the 1990s in Erlangen. Discussion of the scientific advances,
achieved also in other countries like Japan and the USA, was held (not limited to but
also) in The International Academy for Production Engineering (CIRP), document-
ing the milestones in numerous papers and 2 keynote papers. These keynote papers
‘Microforming’, [Gei01] and ‘Size effects in manufacturing of metallic components’
[Vol09] are key documents about the development of micro metal forming. The
relevance of size effects is due to the fact that these effects are the reason why
knowledge from (macro) metal forming cannot be transferred easily to the micro
range. These effects have been the topic of a Priority Program (SPP 1138) funded by
the Deutsche Forschungsgemeinschaft (DFG) in the period from 2002 to 2008.
Three categories of size effects are specified, taking their names from the feature
that is kept constant: density, shape and structure. Fundamental knowledge con-
cerning size effects is documented in the book “Micro Metal Forming” [Vol13].
Specific features are:
1. The size or at least one of the dimensions of the produced parts is comparable
with the grain size of the material used, resulting in hard to control material
behavior.
2. The very small volume of the parts changes the failure behavior due to different
probabilities of the occurrence of a defect in a particular workpiece, if homo-
geneous defects with low density exist in the raw material.
3. The very low weight (typically between 100 lg and 10 mg) of the (raw) parts
makes handling difficult due to, for example, adhesion effects. Therefore parts
should integrate multiple functions to reduce the number of components in an
assembly and to minimize the number of handling and joining operations. On
the other hand, the small weight might allow the use of more expensive
materials or enable new processes.
4. Quality assurance becomes more difficult compared to macro parts, as many
methods usually employed cannot be used for the measurement of micro part
dimensions. Also the (scaled down) tolerances interfere greatly with the preci-
sion of the metrology, making the use of methods like statistical process control
(SPC) impossible.
Research in Collaborative Research Centers (CRC) started in 1998 by several
CRC, each addressing a special aspect of micro technology. The aim of SFB 440
was the Assembly of Hybrid Microsystems, SFB 499 focused on the development,
production and quality assurance of molded micro components of metallic and
ceramic materials and SFB 516 addressed the design and production of active
microsystems. From 2010–16 a research group “Small Machine Tools for Small
Workpieces” made new approaches for machine tools. In the period 2007–2018 the
Collaborative Research Center “Micro Cold Forming” (SFB 747) with about 60
scientists worked on topics relevant for the further development of mass micro
metal forming.
1.2 Aim of the SFB 747

Frank Vollertsen* and Sybille Friedrich
The central concern of the Collaborative Research Center (CRC) “Micro Cold
Forming” is the provision of processes and methods for the production of metal
micro parts by forming, whereby all essential aspects for the forming process, from
material development through component testing to process design, are included.
With the resulting knowledge of the mechanisms and correlations, a purposeful
process design is made possible for the process-reliable production of metallic
components with a size of less than 1 mm and the necessary tools. Batch sizes over
1 million parts are in focus. As a basis for this, the CRC serves industrial
requirements with a manufacturing frequency of typically 300 parts/minute. By
definition [Gei01], micro forming deals with parts having dimensions less than
1 mm in at least two directions. For further limitation of the research program, sheet
thicknesses of 10–200 µm and wire diameters of 200–1,000 µm are specified.
The Collaborative Research Center focuses on micro components that are pro-
duced in unit quantities or batch sizes over 1 million parts. The increase in the
number of variants results in the need for the reconfigurability of the production
lines with the aim of making the production of micro parts more flexible. There is
demand for individual processes that are easy to handle and flexible in use and thus
support a modular production. Here, the planning of the processes, the definition of
the interfaces and the monitoring strategies are of particular importance in order to
be able to quickly realize economically the start-up of the production of different
micro parts. The materials used in the central process chains are steel (1.4301),
aluminum (99.5) and copper (E-Cu58), as well as their alloys. The microstructure in
terms of homogeneity, grain size and isotropy plays an important role in the
formability. These factors are of particular importance for the alloys of the metals
listed above, since the production-related variables determine them. In addition,
other materials and combinations of materials are used, which can exploit the
opportunities offered with regard to component and workpiece design. The goal is
the production of the already mentioned micro technical components. Microsystem
technology (MST) and micro electromechanical systems (MEMS) are explicitly not
the subject of the CRC research.
1.3 Structure and Partners
Frank Vollertsen* and Sybille Friedrich

The research program gives the Collaborative Research Center a broad basis, from
the development of materials through the processes and their optimization to the
planning aspects of micro forming technology production. In order to visualize the
internal collaboration, three perspectives on the structure of the CRC were defined,
by means of which the CRC is presented as a whole (see Fig. 1.1). As a super-
ordinate element, a demonstrator was realized, on which all subprojects describe
their research progress in terms of the hardware, concept or virtual contribution.
Research work was coordinated using two further structural elements—the project
structure and the content relation.
The CRC offers a comprehensive overview of all aspects of micro forming
technology for sheet metal and massive forming with regard to the safe production
of micro components. Based on this objective, the structure of the Collaborative
Research Center with the project areas processes, characterization and optimization
results. Table 1.1 shows the project structure of the Collaborative Research Center.
A—Processes
Project area A of the CRC “Micro Cold Forming” deals with fundamental questions
of the single processes. The forming processes themselves are examined, as well as
Fig. 1.1 Perspectives of the

structure of the CRC allowing
optimal internal interaction
and collaboration
Table 1.1 Project Structure of the Collaborative Research Center (SFB 747). Line 1: DFG Short
number and title, Line 2: Running Head(s) of the project, Line 3: Duration of the project (start and
end), Line 4: Link for further details
A: Processes B: Characterization C: Optimization T: Transfer
A1 PVD-sheets B1 Deformation C1 Tool T2 Refining
Zoch, Mehner behavior Materials Kuhfuß
2007–2018 Vollertsen Partes 2015–2016
Section 6.3 2007–2010 2007–2013 Section 2.4
[Hu10] [Feu13]
A2 Heat treatment B2 Distribution based C2 Surface T3 Micro cavity
Zoch simulation optimization Bergmann,
2007–2018 Brannath, Schmidt, Hunkel Riemer, Maaß Lütjen
Section 6.4 2007–2014 2007–2018 2015–2016
[Lüt14] Section 4.5 Section 5.3
A3 Material B3 Tool duration C4 T4 Micro milled
accumulation Vollertsen, Bergmann Simultaneous dental products
Vollertsen, 2007–2018 Engineering Riemer, Maaß
Schmidt Section 4.2 Lütjen 2015–2017/1.
2007–2018 2007–2018 Hj. Section 4.6
Section 2.2 Section 3.3
A4 Material B4 Material strength C5 Linked parts T5 TEC-Pro
displacement Zoch, Clausen Tracht, Kuhfuß Vollertsen
Kuhfuß 2007–2018 2011–2018 2015–2016
2007–2018 Section 5.5 Section 3.2 Section 4.4
Section 2.3
A5 Laser contour B5 Safe processes C6
Goch, Vollertsen Bergmann, Goch, Lütjen Spray-graded
2007–2018 2007–2018 tool steels
Section 4.3 Section 5.2 Schulz
2011–2017
Section 6.2
A6 Friction B7 Process stability
polishing Vollertsen
Brinksmeier 2011–2018
2007–2017 Section 2.5
Section 4.6
further process steps before and after the forming step. At the beginning of the
interacting processes is the production of semi-finished products for the micro
forming production.
B—Characterization
With regard to new materials, tools and processes for micro forming, an exact
knowledge concerning the material behavior of both the workpieces and the tools
and their interaction is essential. This is subject of the project area B characteri-
zation of this Collaborative Research Center.
C—Optimization
In order to meet the precision and speed requirements of a reliable and
cost-effective production process, this project area uses the results of process
development and the characterization of basic material properties and product
parameters to optimize the key production steps.
T—Transfer
Research enhancing the basic research results of the CRC is examined in transfer
projects, each realized in cooperation with an industry partner.
The results of the complete funding period of all projects running in 2016 or later
are described in Sects. 2.1–6.4. In addition, a special approach for in situ geometry
measurement in fluids, using confocal fluorescence microscopy, is presented in
Sect. 5.4.
Internal Cooperation
Collaborating Institutes
Eight institutes, located on the campus of the University of Bremen, collaborate
with their special knowledge to achieve the collective aim. They are listed in
alphabetical order together with the most important research areas covered within
the CRC. The names of the actual responsible heads of the projects are given in
brackets:
BIAS—Bremer Institut für angewandte Strahltechnik: Laser material processing,
sheet and bulk metal micro forming (Prof. Dr.-Ing. Frank Vollertsen); optical
metrology (Prof. Dr. rer. nat. Ralf Bergmann).
BIBA—Bremer Institut für Produktion und Logistik: Logistics and simultaneous
engineering (Dr.-Ing. Michael Lütjen).
BIMAQ—Bremer Institut für Messtechnik, Automatisierung und
Qualitätswissenschaft: Process control including metrology, quality assurance
(Prof. Dr.-Ing. Andreas Fischer, Prof. Dr.-Ing. Gert Goch).
bime—Bremer Institut für Strukturmechanik und Produktionsanlagen: Bulk
metal forming including machine development (Prof. Dr.-Ing. Bernd Kuhfuß);
process chain layout and automatization (Prof. Dr.-Ing. Kirsten Tracht).
IfS—Institut für Statistik: Monte-Carlo simulation and statistics (Prof. Dr. Mag.
rer. nat. Werner Brannath).
Leibniz—IWT Leibniz-Institut für Werkstofforientierte Technologien: Physical
vapor deposition, heat treatment and mechanical testing (Prof. Dr.-Ing.
Hans-Werner Zoch, Prof. Dr.-Ing. Brigitte Clausen, Dr.-Ing. Andreas Mehner, Dr.-
Ing. Alwin Schulz, Dr.-Ing. Martin Hunkel).
Leibniz—IWT (LFM) Leibniz-Institut für Werkstofforientierte Technologien,
Laboratory for Precision Machining: Cutting, machining and polishing (Prof. Dr.-
Ing. Prof. h.c. Dr.-Ing. E.h. Ekkard Brinksmeier, Dr.-Ing. Oltmann Riemer).
ZeTeM—Zentrum für Technomathematik: Industrial mathematics (Prof. Dr. Dr.
h.c. Peter Maaß), simulation systems (Prof. Dr. Alfred Schmidt).
Fields of Competence
The global approach, which spans a bridge from the base materials to the finished
component in terms of micro forming technology, is a specialty of this
Collaborative Research Center. Two exemplary cycles are shown in Fig. 1.2.
Within the fields of competence, working meetings focused on material aspects, on
process design including the demonstrator and on the aspects of component char-
acterization as well as on tool-specific issues.
In Chaps. 2–6, more can be learned about the knowledge gained in the fields of
competence micro forming, tooling, quality control and characterization, as well as
concerning new materials for thin sheets and adapted tools, which were especially
developed to fulfill the needs of micro forming aspects.
Communication with the International Scientific Community
An essential device is the discussion of research results at relevant conferences and
congresses, as well as publications in international journals and books. In addition,
there are contacts with renowned scientific networks, such as acatech, AGU,
AHMT, AWT, CIRP, euspen, ICFG, IDDRG, I2FG, GCFG, GQW, MHI, SME,
WAW, WGP und WLT by the principal investigators and participating institute
directors.
The book “Micro Metal Forming”, written by the scientists of SFB 747 and
edited by F. Vollertsen, was published by Springer in the book series “Lecture
Notes in Production Engineering” in 2013 [Vol13].
Materials Friction polishing Tools

Tool materials (SLM)
Laser contour
Spray-graded tool steels
Surface optimization
PVD sheets
Tool durability
Heat treatment Process stability
Material accumulation Micro forming Material displacement
Safe processes
Linked parts
Distribution based simulation
Component strength Simultaneous Engineering
Quality control and characterization Process design

Tool cycle
Workpiece cycle
Fig. 1.2 Exemplary display of one workpiece and one tool cycle within the fields of competence
of CRC (for space reasons without transfer projects)
Further, the research of the CRC has been sustainably supported by numerous
impulses gained by close collaboration with international partners in relevant
research fields, such as:
Micro forming (Prof. Ming Yang, Tokyo Metropolitan University, Japan)
Laser material processing and micro milling (Prof. Frank E. Pfefferkorn,
University of Wisconsin-Madison, USA)
Microstructuring of polycrystalline diamond (Dr. Yiqing Chen and Prof. Liagchi
Zhang of the University of New South Wales in Australia)
Wear (Prof. Hans Norgaard Hansen and Dr. Guido Tosello of the Technical
University of Denmark (DTU))
Mathematical methods (Prof. Pham Quy Muoi, The University of Danang,
Vietnam; Dr. Jonathan Montalvo-Urquizo, CIMAT Centro de Investigación en
Matemáticas, Guanajuato, Mexico; Prof. Eberhard Bänsch, University Erlangen).
The CRC (co)organized the following scientific conferences:
The national Colloquium Micro Production has taken place biannually since
2003. The joint organization of the collaborative research groups of micro tech-
nology and their follow-up projects have the overall objective of micro technical
questions. The conference was hosted in Bremen in 2009 and 2017. The event was
also used intensively by the industrial partners for the exchange of information.
Since 2014 the CRC has established a session “micro forming technologies” at the
International Conference on Nanomanufacturing (nanoMan), which is biannually
organized by the International Society for Nanomanufacturing. The International
Conference on New Forming Technology (ICNFT) is an inspiring forum for
researchers and professional practitioners to discuss aspects of leading-edge novel
forming technologies. The steering committee of the conference comprises mem-
bers from BIAS, Germany, Harbin Institute of Technology, China, the University of
Birmingham, UK and the University of Strathclyde, UK. The CIRP and DFG
sponsored 5th ICNFT 2018 took place in Bremen, Germany. In 2018, special
sessions focusing on micro cold forming were included. Within this scope, the CRC
held its final Colloquium in exchange with international specialists.
Additionally, the CRC presented itself at fair trade stands, for example at the
International Conference on Technology of Plasticity (ICTP) in 2011 and 2017.
Around 700 international, mainly scientific, participants were informed about the
collaborative focus and research results.
Cooperation with Industry
In addition to the scientific national and international networks, an industrial
working group was established in the first funding period, with the aim of trans-
ferring the research results to industry and orienting the scientific research to current
needs. Members of the industrial workgroup are:
BEGO Medical GmbH, Robert Bosch GmbH, Uni Bremen Campus GmbH,
Felss GmbH, Harting Applied Technologies GmbH & Co. KG, Hella
Fahrzeugkomponenten GmbH, Huber und Suhner AG, IFUTEC GmbH, Keyence
GmbH, Philips Consumer Lifestyle B.V., SITEC Industrietechnologie GmbH, SLM
Colloquium Micro Production Int. Conference on New Forming Technology

biannual –ICNFT
with final
in Bremen: colloquium
2009 SFB 747
2017 2018
Industrial meetings Int. Conference on Technology of Plasticity
International
–ICTP
National
annual
2011
2017
Trade Fair for Production in the North Hannover Trade Fair

–NORTEC
2010
2014 2013
2017 2018
Fig. 1.3 A selection of national and international conferences and exhibition stands on trade fairs
for research and industry, (co)organized by SFB 747
Solutions GmbH, Stüken GmbH & Co. KG, Tyco Electronics GmbH & Co. KG,
Wafios Umformtechnik GmbH, Werth Tool MT GmbH, Weidmüller Interface
GmbH & Co. KG.
The consortium has been regularly provided with information from the CRC and
an annual industry colloquium was held to identify co-operation issues. From this
consortium also the transfer themes emerged (Fig. 1.3).
Definition of Demands on Mastering Mass Production of Micro Parts
Research with the aim of providing new processes and methods especially adapted
to the production of micro parts in high numbers took place in three funding periods
(see Fig. 1.4).
From 2007 to 2010, the researchers developed new processes and methods that
are especially designed for micro forming. The findings were improved in the
second period (2011–14) to be more stable and to be used for the production of
more complex products, while the processes were kept as easy as possible. In the
last period, the knowledge was increased by upscaling the number of parts and the
transfer to multistage processes.
The challenges arising from the goal of mastering the mass production of micro
parts, which are to be solved with different weighting in the individual subprojects
(see Table 1.1), consisted in the shortening of the process times, the increase in the
forming speed, the modification of the tribology and the heat balance, as the higher
clock rates result in an effectively higher power dissipation in the process zones.
This is followed by the demand for faster transport, faster measurement and control
processes, mastery of the tribology, thermal balance of the processes, and the
dispersion of material properties (see Fig. 1.5). The main results of the
1. period 2. period 3. period
New processes and Improve complexity Upscaling the number

methods and stability of parts and
multi stage forming
forming forming
materials materials Mastering the speed of
tools tools process
characterization characterization production
process design process design innovation
2007-2010 2011-2014 2015-2018
Fig. 1.4 Funding periods and their main research focus
innovation process production

speed speed speed
measurement and
process design tribology quality control
scatter handling
design of
production
systems thermal aspects
Fig. 1.5 Mastered aspects for a high quality and economic mass production of more than one
million batches/micro parts
Collaboration Research Center “Micro Cold Forming” concerning mastering these

aspects of innovation speed, process speed and production speed are summarized in
Sect. 1.4.
1.4 Main Results
1.4.1 Innovation Speed
1.4.1.1 Process Design
Ann-Kathrin Onken and Kirsten Tracht*

The design and development of new products and production processes is
time-consuming. For faster design of parts, and hence a higher innovation speed,
knowledge about the manufacturing processes, parts and their interdependencies is
required. This knowledge also enables the simulation and modeling of processes
and process steps.
To speed up the design of parts, one opportunity is the development of a
modular design system, as shown for linked parts in Sect. 3.2. Linked parts are left
in the material they are made of, for example, foil or wire. The remaining material
of the interconnection can be used for the implementation of functions that assist in
manufacturing processes. Besides the orientation of the parts, the interconnections
are appended with functional elements, which are relevant for the handling, such as
for the positioning of parts as concerned in the modular design system.
Basic knowledge about the process parameters and their influence on the
workpiece are major results from the CRC 747 and build an important basis for fast
adaptation to other products, parts or manufacturing processes.
Laser-based free-form heading (Sect. 2.2) is an alternative process chain in the
micro range for the production of conventional upsetting and metal forming. It can
be applied on rod and on thin metal sheet. With this method, which only works in
the micro range, thermal upsetting relations to 500 are possible. The aim of three
hundred line-linked parts per minute are realized, which can be formed in a further
step. A validated 3D simulation enables the parameter identification and process
analysis for free form heading.
Rotary swaging, which is well implemented in the macro range, for example, for
producing parts for the automotive industry, has been adapted to the micro range.
The two main variations of the process, infeed and plunge rotary swaging, were
investigated in the CRC (Sect. 2.3). In order to increase the productivity in the
micro range, the process speed can be increased. However, this could lead to
failures, particularly due to inappropriate material flow against the feed direction.
The findings show that, with additional measures, both the radial and the axial
material flow can be controlled, and in both cases the productivity in micro rotary
swaging can be increased by up to a factor of four. Furthermore, adjusting the axial
positioning of the workpiece during plunge rotary swaging allows a higher diversity
to be achieved for the geometry of the swaged part.
On the basis of rotary swaging, the refining (Sect. 2.4) deals with the condi-
tioning of wire semi-finished products for the subsequent forming processes. The
results show how the formability and the geometrical diversity of semi-finished
parts are prepared by process modifications in rotary swaging tools and kinematics.
These results can be adapted to other forming processes like deep drawing and
extrusion.
In the case of single and multistep deep drawing, the prediction of the influence
of the process parameters and tools on the geometrical properties of parts is also an
aim of the investigations about the process stability (Sect. 2.5). The objective is the
definition of the interaction of the tool geometry and the stability of a multi-stage
micro-drawing process. The results show how to determine allowable and
achievable manufacturing tolerances, and wear of the tools’ geometry to ensure a
stable manufacturing process while producing very large quantities.
Within the competence field of tools, especially the progress in laser chemical
machining (Sect. 4.3) enables precise quality control during the manufacturing of
metallic micro forming tools. The combination of thermal modeling to define the
temperature regime for a disturbance-free removal and closed-loop quality control
to compensate the deviations of quality features opens up the possibility of
dimensionally and geometrically flexible micro machining. In addition, a developed
machining strategy consisting of roughing and finishing steps is used to improve
both the microstructural and the topographical tool quality.
By developing the method of non-linear inverse problems, it was possible to
allow optimized process parameters for the manufacturing process of tribologically
optimized micro forming dies (Sect. 4.5).
The impact of the process parameters on the material properties is presented by
the results of two investigated processes. The results of the PVD sheet production in
Sect. 6.3 show how magnetron sputtering is established for the generation of thin
foils with high strength and good forming behavior. The results clarify how the
thickness of the coating is adjustable by changing the transport speed and the size of
the exposure area.
In the micro range, heat treatment in a drop-down tube furnace, where the parts
are heat-treated as they are falling, is possible because of the size effects (Sect. 6.4).
The investigations make it possible to retain the accuracy of the shape as well as the
specific setting of properties. Therefore, parameters like the falling time, tempera-
ture areas within the furnace, and quenching medium are considered.
Several manufacturing processes for forming tools with tailored material prop-
erties that lengthen the tool lifetime were established. One option is tool manu-
facturing by selective laser melting [Flo16]. Co-spray forming with selective heat
treatment afterwards allows adapted tool steels and properties in the specific regions
of the tool, with a gradual material transition in between to ensure good bonding
(Sect. 6.2).
1.4.1.2 Design of Production Systems
Ann-Kathrin Onken and Kirsten Tracht*

The planning and configuration of process chains constitutes a major factor of
success for the industrial production of metallic micromechanical components, due
to the occurrence of size effects, the inherently small tolerances, and the small
geometrical dimensions of the workpieces. For this reason, methodologies and
recommendations for the design of production systems for micro mass production
are required. Within this context, CRC 747 focuses on two different aspects with
two different perspectives.
The first is the widening of the tolerance field (Sect. 3.2). This methodology
follows a super-ordinated point of view on the process chain. Based on measured
geometrical dimensions of linked parts, trends occurring that are, for example,
caused by wear are used for matching, and design adjustments. Therefore, a
reduction of surplus parts as well as the increased durability of tools is achieved.
The production of linked parts is crucial for this methodology. Due to the retention
of the production order, the parts are measured to identify trends concerning geo-
metrical deviations, which are used for building homogeneous trend sections. These
sections are used for matching linked parts for building assemblies. Hence a soft-
ening of the tolerances, similar to selective assembly, is achieved. Selective
assembly is usually applied to scenarios where processes are hard to control. In
micro mass production, this specific matching enables a widening of the tolerance
field. The feedback loop to the design stage enables further increases in the outcome
by a stepwise adjustment of the nominal value and new combinations of parts. With
the adjusted nominal value, the identified sections, and matchings, further batches
are produced and assembled.
The second perspective focuses on detailing the interdependencies between and
within processes by considering the effects of single parameters on the production
result. Small variations in single parameters can have significant influences along
the process chain and finally interfere with the compliance with tolerances. For this
reason, the µ-Process Planning and Analysis methodology (Sect. 3.3) covers all
phases from the process and material flow planning to the configuration and
evaluation of the processes and process chain models. The process configuration
relies on so-called cause–effect networks, subsuming the relevant logistic and
technical parameters of the corresponding processes and describing their relation-
ships to each other. By using these networks, µ-Process Planning and Analysis
enables a fast evaluation of different process configurations (e.g. the use of different
materials or different production velocities) already during the planning stages. The
networks enable an assessment of the impacts of different choices on the follow-up
processes or the production system in general. Thereto, µ-Process Planning and
Analysis can directly reflect changes to the configuration in the integrated material
flow simulation and evaluate these configurations, e.g., regarding work-in-progress
levels, lead times or the products’ estimated qualities.
1.4.2 Micro Mass Forming
1.4.2.1 Tribology
Florian Böhmermann* and Oltmann Riemer*

Tribology is one major concern in the development of micro cold forming pro-
cesses. Size effects lead to changes in the predominant friction mechanism towards
adhesion, as well as a reduction of the effectiveness of lubrication. This is asso-
ciated with an increase of friction and has an impact on the wear behavior.
Furthermore, micro forming dies and work pieces show anisotropic behavior in
wear or non-predictable malfunctions, as the geometrical features and micro
structure are of about the same size. Thus, the development of robust micro cold
forming processes presumes an understanding of the mechanisms of friction and
wear in the micro regime. The main work within CRC 747 was first to determine
the wear mechanisms in micro cold forming processes and to derive measures to
avoid and reduce wear (Sect. 4.2). The second area of investigation was the
development of dry micro deep drawing processes utilizing textured forming dies.
The work here comprised the development of new and geometrically scaled down
experimental setups for tribological investigations and the generation and appli-
cation of textured surfaces with friction-reducing properties (Sect. 4.5).
Investigation and Avoidance of Wear
The investigation of forming die wear in micro deep drawing was carried out within
a combined blanking and deep drawing process on a high dynamic forming press
with two linear direct driven axes. Here, up to 300,000 micro cups were machined
in a row. Replication techniques were applied to allow for an ex situ forming die
wear investigation and the forming die to remain in the machine. The combined
blanking and forming die suffered from failure of the cutting edge rather than
abrasive wear of the drawing edge radius (see Sect. 4.2). The dies’ malfunction was
traced back to the comparatively coarse grain of the applied cold working steel. The
application of forming dies made from fine-grained tool steel generated by powder
metallurgy helped to overcome this issue.
Furthermore, a combined blanking and forming die from the alternative material
Stellite was introduced. The die was manufactured by laser selective melting
(SLM) and micro grinding for contour finalization. Comparatively high hardness
and excellent toughness allowed for the successful forming of 231,000 micro cups
in a row (see Sect. 4.5 and [Flo16]).
With regard to the investigation of adhesive wear in micro rotary swaging, dry
machining of aluminum Al99.5 workpieces was carried out. Distinct amounts of
cold-welded aluminum were found on the dies after the experiments (Sect. 2.3).
With the aim of avoiding adhesion, a fracture-tough, tungsten-doped diamond-like
carbon (DLC) hard coating system was developed suitable for the particular
application on micro rotary swaging dies with small geometric features (Sect. 6.3).
Subsequent dry micro rotary swaging experiments against aluminum workpieces

applying DLC hard coated forming dies showed a distinct reduction in adhesive
wear. This allowed the feed velocity to be doubled, achieving higher degrees of
deformation in a single process step and increasing the forming die life by a factor
of three.
With the aim of providing wear-resistant tool steels with improved and locally
adapted mechanical properties, a new material generation process was developed:
co-spray forming. In co-spray forming, melts of different materials are sprayed onto
a substrate, forming a deposit with the finest microstructure and gradient zones
between different material layers. Subsequently, the generated material is hot rolled
and heat treated. Micro rotary swaging dies were made from co-sprayed material
composed of two different hot working steels. Subsequently, these dies were suc-
cessfully applied in infeed rotary swaging experiments (Sect. 6.2).
The application of cemented carbides as material for micro forming dies is a
promising measure to reduce the abrasive wear and plastic deformation of forming
dies. This is due to cemented carbides’ significantly higher hardness compared to
hardened tool steels, together with their toughness against impact loads. However,
machining of cemented carbides in small geometrical dimensions with features
sizes down to 100 µm is challenging, e.g. due to strong geometrical limits to the
application of grinding. Micro milling applying novel ball endmills with cutting
edges from binderless polycrystalline diamond (PCD) is an alternative approach
that provides both comparatively high material removal rates and a sufficient sur-
face finish. Machining experiments with binderless PCD ball endmills were carried
out on tungsten carbide samples of different compositions. It was found that
especially fine-grained materials (grain sizes <1 µm) provide the best machining
results. Crack-free machining was achieved and ductile inter-crystalline cutting was
identified as the predominant material removal mechanism. Further work showed
the distinct dependence of the machining result, i.e. the surface roughness, on the
machining strategy: this is up- and down-milling. Down-milling provoked distinct
chatter and reduced the machining quality. Furthermore, wear mechanisms of the
applied micro endmills were identified in dependence on the process parameter feed
per tooth. This allowed suitable machining parameters to be derived for the
machining of micro forming dies from cemented carbide with a geometrically
defined cutting edge (Sect. 4.5).
On top of these measures with respect to channeling and avoiding wear in micro
forming, the application of diamond as a tool material has been advanced. The
outstanding properties of diamond, with a low friction coefficient in tribological
contact with metals, were applied beneficially, and additionally the diamond tool
surfaces were micro-structured for friction control. Therefore, a friction polishing
process was developed and the principal mechanisms governing the machining of
diamond by using thermo-chemical effects were elucidated (Sect. 4.7).
Micro Tribometry
Micro deep drawing processes, obviously, are characterized by only small areas of
contact between the tool—this is the die and the blank holder—and the workpiece.
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* Pronounced Yule in the original.
"Mostly," answered Willi, with slight hesitation, while Lili, remembering their various
deviations from the paths of righteousness, decided to change the subject of conversation,
and gaily embraced her father instead. Willi and Lili, the twins, were exactly eight years
old and were so inseparable that nobody even spoke of them separately. They always
played together, and often undertook things which they had a clear glimmering that they
should not do.
"And you, Rolf, how are you?" said the father, next, to a boy about twelve years old with a
broad forehead and sturdy frame. "Are you working hard at your Latin and have you made
up some nice riddles?"
"Yes, both, papa. But the others won't ever try to guess them. Their minds are so lazy, and
mamma never has time."
"That is too bad, and you, Paula?" continued the father, drawing to him his eldest daughter,
who was nearly thirteen. "Are you still longing for a girl friend, and do you still have to
walk about the garden alone?"
"I haven't found anybody yet! But I am glad you are back again, papa," said the girl,
embracing her father.
"I suppose you are spending your holidays in a useful fashion, Jul?" asked the father,
shaking hands with his eldest.
"I try to combine my pleasure with something useful," replied Jul, returning his father's
handshake. "The hazel nuts are ripe now, and I am watching over their harvest. I also ride
young Castor every day, so he won't get lazy."
Julius, who was seventeen years old, and studied at a high school of the nearest town, was
home for his holidays just now. As he was very tall for his age, everybody called him "big
Jul."
"I must ask you to continue your greetings in the garden, papa. All kinds of surprises await
you there," began Jul again, coming up to his father, who was pleasantly greeting Miss
Hanenwinkel, the children's governess and teacher.
But Jul had to pay dearly for this last remark. Immediately Willi and Lili flew at him from
behind, enjoining him to silence by pinching and squeezing him violently. Fighting them off
as best he could, he turned to Lili: "Let me go, little gad-fly. Just wait, I'll lead up to it
better." And turning towards his father he said loudly, "I mean in the garden where mother
has prepared all kinds of surprises you won't despise. We must celebrate by having
something to eat, papa."
"I agree with you; how splendid! Perhaps we shall even find a table spread under my apple
tree. I should call that a real surprise!" cried the father, delighted. "Come now!"
Giving the mother his arm, he went out, followed by the whole swarm. Lili and Willi were
thrilled that their papa thought this was the only surprise in store for him.
Upon stepping outside, the parents stood immediately under a triumphal arch; at both
sides hung small red lanterns which lit up the large hanging board on which was a long
inscription.
"Oh, oh," said the father, amazed, "a beautiful triumphal arch and a verse for my welcome.
I must read it." And he read aloud:
"We all are here to welcome you beside the garden gate;
And since you've come, we're happy now, we've had so long to wait.
We all are glad, as glad can be, our wishes have come true;
You've got back safe, and we have made this arch to welcome you."
"Beautiful, beautiful! I suppose Rolf is the originator of this?"
But Willi and Lili rushed forward crying, "Yes, yes, Rolf made it, but we invented it. He
made the poem, and Jul set up the poles, and we got the fir twigs."
"I call this a wonderful reception, children," cried the delighted father. "What lovely little
red, blue and yellow lights you have put everywhere; the place looks like a magic garden!
And now I must go to my apple tree."
The garden really looked like an enchanted place. Long ago the small colored lanterns had
been made, and Jul had fastened them that morning on all the trees and high bushes of
the garden. While the greetings were taking place in the house, old Battist and Trine had
quickly lit them. The branches of the apple tree also were decorated with lights, making it
look like a Christmas tree, with the apples gleaming out between the lanterns. They threw
their light down on the table with its white cloth on which the mother had set the large
roast, tempting the guests with the special wine for the occasion and the high pile of apple
tarts.
"This is the nicest festival hall I can imagine!" exclaimed the father happily, as he stood
under the sparkling tree. "How wonderful our dinner will taste here! Oh, here is a second
inscription."
Another white board hung down on two strings from the high branches behind the trees.
On it was written:
"Happy all at my first are reckoned,

Christmas is in the state of my second,
And for my whole the feast is spread
With candy, nuts and gingerbread."
"Oh, I see, a riddle; Rolf must have made this for me!" said the father, kindly patting the
boy's shoulder. "I'll set to work guessing as soon as we have settled down. Whoever
guesses the riddle first may touch glasses with me before the others. Oh, how pleasant it
is to be together again."
The family sat down under the tree, and the conversation soon began to flow. From big Jul
down to little Hun there seemed to be no end of all the experiences everybody had to tell.
A sudden silence fell when the father pulled out from under his chair a large package,
which he promptly began to unpack. The children watched his motions with suspense,
knowing that a present for everybody would now come to light. First, came shining spurs
for Jul, then a large blue book for Paula. Next emerged a rather curious object, turning out
to be a large bow with a quiver and two feathered arrows, a present for Rolf. As the father
took out the fine arrows with sharp iron points, he said with great emphasis:
"This weapon belongs to Rolf only, who knows how to use it. As it is no toy, Willi and Lili
must never think of playing with it. Otherwise they might hurt somebody with it. It is
dangerous, remember."
A gorgeous Noah's ark containing many kinds of animals in pairs and a Noah's family was
presented to the twins. The men all held big staffs and the women carried large umbrellas,
much needed while going on board the ark. For little Hun, who came last, a wonderful
nutcracker came to light, whose face seemed doomed to uninterrupted sorrow for all the
tragedies of this world. His mouth stood wide open when not in action, but when screwed
together, he cracked nuts in the neatest fashion with his large, white teeth. The presents
had to be shown properly and commented upon, and the admiration and joy knew no
bounds.
Finally the mother resolutely got up to tell the children to go to bed. Their usual bedtime
was long since past. As the father got up, he asked with a loud voice, "Yes, but who had
guessed the riddle?"
No one had done so, as all except Rolf had completely forgotten it.
SHE HAD BEEN LOST IN EVERYTHING

SHE HAD PARTLY SEEN AND HEARD
"But I guessed it," said the father, no other answer being heard. "I suppose it is
homecoming. Isn't it, Rolf? Let me touch your glass now and also let me thank you for the
riddle."
While Rolf joyfully stepped up to his father, several frightened voices cried out, "Fire, fire!"
The next moment, everyone leaped from their seats, Battist and Trine came running out
with bottles and buckets from the kitchen, and Hans came from the stable with another
bucket. All rushed about shrieking wildly, "The bush is on fire, the hedge is on fire." The
confusion and noise was truly amazing.
"Dora, Dora!" a wailing voice called down to the little garden of the neighboring cottage,
and the next moment Dora hastened into the house from her place of observation. She
had been so lost in everything she had partly seen and heard that she had not realized
that she had been squatting on the ground for two full hours.
Upstairs, the aunt in grief and fright had pulled her belongings from the wardrobes and
drawers and had piled them high as for immediate flight.
"Aunt Ninette," said Dora timidly, conscious of having remained away too long. "Don't be
frightened any more. Look, it is dark again in the garden over there and all the lights are
out."
Upon gazing over, the aunt saw that everything was dark and the last lights had been put
out. Now a very dim lantern approached the apple tree. Probably somebody was setting
things in order there.
"Oh, it is too terrible! Who could have guessed it!" moaned the aunt. "Go to bed now,
Dora. We'll see tomorrow whether we shall move or leave the place entirely."
Dora quickly retired to her room but she could not go to sleep for a long, long while.
She saw before her the garden and the gleaming apple tree, heard the merry children's
voices and also, their father's pleasant, happy words. She could not help thinking of her
own dear father who had always been willing to listen to her, and she realized how
fortunate her little neighbors were. She had felt so drawn to the children and their kind
parents, that the thought of moving away from the house quite upset her. She could not
go to sleep for a long, long while, for her mind was filled with the recent impressions.
Finally her own beloved father seemed to be gazing down at her and saying the comforting
words as he used to do:
"'Yet God keeps watch above us

And doeth all things well.'"
These words were still in her mind as she went to sleep, while the lights, the gleaming tree
and merry children across the way followed her into her dreams.
After the fire was put out, Willi and Lili were found to be the culprits. Thinking that Rolf's
riddle would look more beautiful if made transparent from behind like the inscription used
every Christmas behind their tree, "Glory to God on High," they had fetched two lights.
Then standing on a high step which had been used for fastening the inscription, they held
the lights very near the riddle. When no joyful surprise was shown on any of the faces,
they put the lights still nearer, till at last the paper was set on fire, catching the nearby
branches. They owned up to their unfortunate undertaking at once and, in honor of the
festive occasion, were sent to bed with only mild reproof. Of course they were forbidden to
make further experiments with fire.
Soon after, deep quiet reigned in the house, and peacefully the moon shone down over the
sleeping garden and the splendid tall trees.
CHAPTER IV
ALL SIX
"We shall have to move away from here, Mrs. Kurd," were Aunt Ninette's first words the
following morning when she came down to breakfast. "We seem to have come into a
dreadful neighborhood. We had better move today."
Speechless with surprise, Mrs. Kurd stood still in the middle of the room. She looked at
Mrs. Ehrenreich as if she could not comprehend the meaning of her words.
"I mean it seriously, Mrs. Kurd, we must move today," repeated Aunt Ninette.
"But you could not possibly find more delightful neighbors in all Tannenberg, Mrs.
Ehrenreich, than we have here," began Mrs. Kurd as soon as she had recovered from her
amazement.
"But, Mrs. Kurd, is it possible you did not hear the terrific noise last evening? It was worse
than any of the things we especially meant to avoid."
"It was only the children, Mrs. Ehrenreich. They happened to be especially lively because
they had a family party last evening."
"If such feasts are celebrated first by a wild explosion of joy, and end with a fire and an
unspeakable confusion, I call such a neighborhood not only noisy but dangerous. We had
better move at once, Mrs. Kurd, at once."
"I don't believe the fire was intended to take place at the party," Mrs. Kurd reassured the
aunt. "It was probably a little accident and was at once put out. Everything is most orderly
in that household, and I really cannot believe that the lady and gentleman can possibly
want to move on account of such neighbors as we have. You would be sure to repent such
a decision, for no better rooms can be had in all Tannenberg."
Aunt Ninette calmed down a trifle, and began breakfast with Dora and Uncle Titus.
Breakfast was over by that time in the big house, and the father was attending to business
while the mother was looking after her household duties. Rolf, who had a daily Latin lesson
with a pastor of the neighboring parish, had long ago left the house. Paula was having a
music lesson with Miss Hanenwinkel, while Willi and Lili were supposed to review their
work for the coming lessons. Little Hun sat at his table in the corner, examining his
sorrowful looking nutcracker-man.
Now Big Jul, who had just returned from his morning ride, entered the room, his whip in
his hand and the new spurs on his feet.
"Who'll take off my riding boots?" he shouted, flinging himself into a chair and admiring his
shiny spurs. Immediately Willi and Lili flew towards him, glad of a chance to leave their
work.
With not the slightest hesitation, Willi and Lili took hold, and before Jul could prevent it, he
was pulled off his chair, Willi and Lili having hold of him and not the boots. At the last
instant, he had been able to seize the chair, which, however, tumbled forward with him.
Jul cried loudly, "Stop, stop!" which brought little Hun to his big brother's rescue.
Holding the chair from the back, the small boy pushed with all his strength against the
twins. But he was pulled forward, too, and found himself sliding along the floor as on an
ice-slide. Willi and Lili anxious to complete their task, kept up their efforts in utter
disregard of Jul's insistent commands to stop, and the words:
"O, Willi and Lili,

You twins, would you kill me?"
BEFORE JUL COULD PREVENT IT,

HE WAS PULLED OFF HIS CHAIR.
Little Hun shrieked loudly for assistance, till at last, the mother came upon the scene. Willi
and Lili let go suddenly, Jul swung himself back to the chair, and little Hun, after swaying
about for a few seconds, regained his balance.
"But, Jul, how can you make the little ones so wild? Can't you be doing something more
profitable?" the mother admonished her eldest son.
"Yes, yes, I'll soon be at a more profitable occupation, dear mamma. But I feel as if I
helped you with their education," he began in a conciliating tone. "If I keep Willi and Lili
busy with innocent exercise like taking my boots off, I keep them out of mischief and any
dreadful exploits of their own."
"You had better go to your profitable occupation, Jul. What nonsense you talk!" declared
the mother. "And Lili, you go to the piano downstairs at once and practice, till Miss
Hanenwinkel has finished with Paula. Till then Willi must study. I should call it a better
thing, Jul, if you saw to the little ones in a sensible way, till I come back."
Jul, quite willing, promised to do his best. Lili hastened to the piano, but being in a rather
excited mood, she found her fingers stumbling over each other while doing scales. The
little pieces therefore tempted her more and she gaily and loudly began to play:
"Rejoice, rejoice in life

While yet the lamp is glowing
And pluck the fragrant rose
In Maytime zephyrs blowing!"
Uncle Titus and his wife had just finished breakfast when the riding-boot scene took place
in the big house. Uncle Titus went straight to his room and barred the windows, while his
wife called to the landlady, begging her to listen to the noise, herself. But the whole affair
made a different impression on Mrs. Kurd than she had hoped.
"Oh, they have such times over there," said Mrs. Kurd, amused. When Mrs. Ehrenreich
tried to explain to her that such a noise was not suitable for delicate people in need of rest,
Mrs. Kurd suggested Mr. Ehrenreich's taking a little walk for recreation to the beautiful and
peaceful woods in the neighborhood. The noise over there would not last very long. The
young gentleman just happened to be home for the holidays and would not stay long. Lili's
joyful piece, thrummed vigorously and sounding far from muffled, reached their ears now.
"What is that? Is that the young gentleman who is going away soon?" inquired Aunt
Ninette excitedly. "What is coming next, I wonder? Some new noise and something more
dreadful every moment. Is it possible, Mrs. Kurd, you have never heard it?"
"I never really noticed it very much. I think the little one plays so nicely, one can't help
liking it," Mrs. Kurd declared.
"And where has Dora gone? She seems to be becoming corrupted already, and I can't
manage her any more," wailed the aunt again. "Dora, Dora, where are you? This is
dreadful, for she must start on her work today."
Dora was at the hedge again, happily listening to the song Lili was drumming on the piano.
She appeared as soon as her aunt called to her, and a place was immediately chosen near
the window, where she was to sew for the rest of the day.
"We can't possibly stay here," were the aunt's last words before leaving the room, and
they nearly brought tears to Dora's eyes. The greatest wish of her heart was to stay just
here where so many interesting things were going on, and of which she could get a
glimpse now and then. Through her opening, she could hear a great deal and could watch
how the children amused themselves in their pretty garden. Dora puzzled hard to find a
way which would prevent their moving. However, she could find none.
Meanwhile eleven o'clock had come, and Rolf came rushing home. Seeing his mother
through the open kitchen door, he ran to her.
"Mamma, mamma!" he cried before he was inside. "Can you guess? My first makes—"
"Dear Rolf," the mother interrupted, "I beg you earnestly to look for somebody else; I have
no time just now. Go to Paula. She is in the living room." Rolf obeyed.
"Paula!" he cried from below. "Guess: My first makes—"
"Not now, please, Rolf!" retorted Paula. "I am looking for my notebook. I need it for
making a French translation. Here comes Miss Hanenwinkel, try her. She can guess well."
Rolf threw himself upon the newcomer, Miss Hanenwinkel. "My first makes—"
"No time, Rolf, no time," interrupted the governess. "Go to Mr. Jul. He is in the corner over
there, having his nuts cracked for him. Go to him. See you again."
Miss Hanenwinkel, who had once been in Italy, had in that country acquired the habit usual
there of taking leave of people, and used it now on all occasions. If, for instance, the knife-
sharpener arrived, she would say, "You here again. Better stay where you belong! See you
again." With that she quickly closed the door. If the governess were sent to meet peddlers,
or travelling salesmen coming to the house on business, she would say, "You know quite
well we need nothing. Better not come again. See you again," and the door was quickly
shut. This was Miss Hanenwinkel's peculiarity.
Jul was sitting in a corner, and in front of him, sat little Hun, busy giving his sorrowful
looking nutcracker nuts to crack, which he conscientiously divided with Jul.
Rolf stepped up to the pair. "You both have time to guess. Listen!"
"'My first is just an animal forlorn.

My second that to which we should be heir,
And with my whole some lucky few are born
While others win it if they fight despair.'"
"Yes, you are right. It is courage," explained the quick older brother.
"Oh, but you guessed that quickly!" said Rolf, surprised.
"It is my turn now, Rolf. Listen, for it needs a lot of thinking. I have made it up just this
minute," and Jul declaimed:
"'My first is sharp as any needle's end,

My second is the place where money grows,
My whole is used a pungent taste to lend,
And one you'd know, if only with your nose.'"
"That is hard," said Rolf, who needed time for thinking. "Just wait, Jul, I'll find it."
Herewith, Rolf sat down on a chair in order to think in comfort.
Big Jul and small Hun meanwhile kept on cracking and eating nuts, Jul varying the game
by sometimes trying to hit some goal in the room with a shell.
"I know it!" cried Rolf, overjoyed. "It is pick-pocket."

"Oh, ho, Rolf, how can you be so absurd! How can a pick-pocket smell?" cried Jul,
disgusted. "It is something very different. It's spearmint."
"Yes, I see!" said Rolf, a little disappointed. "Wait, Jul, what is this?"
"'My first within the alphabet is found,

My second is a bread that's often sweet;
My third is something loved by active feet.
My whole means something more than just to go around.'"
"Cake-walk," said Jul with not the slightest hesitation.
"Oh ho, entirely wrong," laughed Rolf, "that doesn't work out. It has three syllables."
"Oh, I forgot," said Jul.
"You see you are wrong," triumphed Rolf. "It is abundance. Wait, I know still another."
"The first—"
"No, I beg to be spared now, for it is too much of an exertion, and besides I must see to
Castor." Jul had jumped up and was running to the stable.
"Oh, what a shame, what a shame!" sighed Rolf. "Nobody will listen to me any more and I
made up four more nice riddles. You can't guess, Hun, you are too foolish."
"Yes, I can!" declared the little boy, offended.
"All right, try then; but listen well and leave these things for a while. You can crack nuts
later on," urged Rolf and began:
"'My first is closest bonds that can two unite,

My second like the shining sun is bright;
My whole's a flower that thrives best in wet ground
And like my second in its color found.'"
"A nutcracker," said little Hun at once. Jul being the little one's admired model, he thought
that to have something to say at once was the chief point of the game.
"I'll never bother with you again, Hun; there is nothing to be done with you," cried Rolf,
anxious to run away. But that did not work so simply, little Hun, who had caught the riddle
fever, insisted upon trying out his first attempt.
"Wait, Rolf, wait!" he cried, holding on to Rolf's jacket. "It is my turn now and you must
guess. My first can be eaten, but you can't drink it—"
"I suppose it's going to be nutcracker!" cried Rolf, running away from such a stupid riddle
as fast as his legs could carry him.
But the small boy ran after him, crying all the time, "You didn't guess it! You didn't guess
it! Guess it, Rolf, guess!"
All at once, Willi and Lili came racing towards him from the other side, crying loudly, "Rolf,
Rolf, a riddle, guess it! Look at it, you must guess it!" and Lili held a piece of paper directly
under Rolf's nose, while Hun kept on crying, "Guess, Rolf, guess!" The inventor of riddles
was now in an extremity himself.
"Give me a chance, and I'll guess it," he cried, waving his arms to fight them off.
"As you can't guess mine, I'll go to Jul," said Hun disdainfully, turning his back.
Rolf seized the small slip of paper, yellow from age, which Lili was showing him. He looked
perplexed at the following puzzling words written apparently by a child's hand:
"My hand.
Lay firmly
Wanted to be
But otherwise
One stays
And each
And now will
This leaf
When the time comes
That the pieces
fit
We'll rejoice
And we'll go
Never."
"Perhaps this is a Rebus," said Rolf thoughtfully. "I'll guess it, if you leave me alone a
minute. But I must think hard."
There was not time for that just then, for the dinner bell rang loudly and the family began
to gather around the large dining' room table.
"What did you do this morning, little Hun?" asked the father, as soon as everybody had
settled down to eating.
"I made a riddle, papa, but Rolf won't guess my riddles, and I can't ever find Jul. The
others are no good, either."
"Yes, papa," eagerly interposed Rolf now, "I made four or five lovely riddles, but no one
has time to guess except those who have no brains. When Jul has guessed one, he is
exhausted. That is so disappointing, because I usually have at least six new ones for him
every day."
"Yes, papa," Willi and Lili joined in simultaneously, "and we found a very difficult puzzle. It
is even too hard for Rolf to guess. We think it is a Rebus."
"If you give me time, I'll guess it," declared Rolf.
"The whole house seems to be teeming with riddles," said the father, "and the riddle fever
has taken possession of us all. We ought to employ a person for the sole purpose of
guessing riddles."
"Yes, if only I could find such a person," sighed Rolf. To make riddles for some one who
would really listen and solve them intelligently seemed to him the most desirable thing on
earth.
After lunch the whole family, including Miss Hanenwinkel, went outside to sit in a circle
under the apple tree, the women and girls with some sewing or knitting. Even little Hun
held a rather doubtful looking piece of material in his hand into which he planted large
stitches with some crimson thread. It was to be a present for Jul in the shape of a cover
for his horse. Jul, according to his mother's wish, had brought out a book from which he
was supposed to read aloud. Rolf sat under the mountain-ash some distance away,
studying Latin. Willi, who was expected to learn some verses by heart, sat beside him. The
small boy gazed in turn at the birds on the branches overhead, at the workmen in the field
below, and at the tempting red apples. Willi preferred visible objects to invisible ones and
found it difficult to get anything into his head. It was a great exertion even to try, and he
generally accomplished it, only with Lili's help. His study-hour in the afternoon, therefore,
consisted mostly in contemplating the landscape round about.
Jul, that day, seemed to prefer similar observations to reading aloud. He had not even
opened his book yet, and after letting his glances roam far and wide, they always came
back to his sister Paula.
"Paula," he said now, "you have a face today as if you were a living collection of worries
and annoyances."
"Why don't you read aloud, Jul, instead of making comparisons nobody can understand?"
retorted Paula.
"Why don't you begin, Jul?" said the mother. "But, Paula, I can't help wondering, either,
why you have been in such a wretched humor lately. What makes you so reserved and out
of sorts?"
"I should like to know why I should be confiding, when there is no one to confide in. I have
not a single girl friend in Tannenberg, and nobody at all to talk to."
The mother advised Paula to spend more time either with her small sister or Miss
Hanenwinkel, who was only twenty years old and a very nice companion for her. But Paula
declared that the first was by far too young and the other much too old, for twenty
seemed a great age to Paula. For a real friendship, people must be the same age, must
feel and think the same. They must at once be attractive to each other and hate the
thought of ever being separated. Unless one had such a friend to share one's joys and
experiences, nothing could give one pleasure and life was very dull.
"Paula evidently belongs to the romantic age," said Jul seriously. "I am sure she expects
every little girl who sells strawberries to produce a flag and turn into a Joan of Arc, and
every field laborer to be some banished king looking for his lost kingdom among the
furrows."
"Don't be so sarcastic, Jul," his mother reproved. "The sort of friendship Paula is looking
for is a beautiful thing. I experienced it myself, and the memories connected with mine are
the sweetest of my whole life."
"Tell us about your best friend, mamma," begged Paula, who several times already had
heard her mother speak of this friendship which had become a sort of ideal for her. Lili
wanted to hear about it, too. She knew nothing except that she recalled the name of her
mother's friend.
"Didn't you call me after your friend's name, mamma?" asked the little girl, and her
mother assured her this was so.
"You all know the large factory at the foot of the mountain and the lovely house beside it
with the big shady garden," began the mother. "That's where Lili lived, and I remember so
vividly seeing her for the first time."
"I was about six years old, and was playing in the rectory garden with my simple little
dolls. They were sitting around on fiat stones, for I did not have elaborate rooms for them
furnished with chairs and sofas like you. Your grandfather, as you know, was rector in
Tannenberg and we lived extremely simply. Several children from the neighborhood, my
playmates, stood around me watching without a single word. This was their way, and as
they hardly ever showed any interest in anything I did, and usually just stared at
everything I brought out, they annoyed me very much. It didn't matter what I brought out
to play with, they never joined in my games."
"That evening, as I knelt on the ground setting my dolls around a circle, a lady came into
the garden and asked for my father. Before I could answer, a child who had come with the
lady ran up to me and, squatting on the ground, began to examine all my dolls. Behind
each flat stone, I had stuck up another so the dolls could lean against it. This pleased her
so much, that she at once began to play with the dolls and made them act. She was so
lively that she kept me spellbound, and I watched her gaily bobbing curls and wondered at
her pretty language, forgetting everything for the moment except what she was doing with
my dolls. Finally, the lady had to ask for my father again."
"From that day on, Lili and I were inseparable friends, and an ideal existence began for me
at Lili's house. I shall never forget the blissful days I spent with her in her beautiful home,
where her lovely mother and excellent father showed me as much affection as if I were
their own child. Lili's parents had come from the North. Her father, through some agents,
had bought the factory and expected to settle here for life. Lili, was their only child, and as
we were so congenial, we wished to be together all the time. Whenever we were
separated, we longed for each other again, and it seemed quite impossible for us to live
apart.
"Lili's parents were extremely kind, and often begged my parents as an especial favor to
let me stay with Lili for long visits, which seemed like regular long feasts to me. I had
never seen such wonderful toys as Lili had, and some I shall never forget as long as I live.
Some were little figures which we played with for whole days. Each had a large family with
many members, of which everyone had a special name and character. We lived through
many experiences with them, which filled us with joy and sorrow. I always returned home
to the rectory laden with gifts, and soon after, I was invited again."
"Later, we had our lessons together, sometimes from the school teacher, Mr. Kurd, and
sometimes from my father. We began to read together and shared our heroes and
heroines, whose experiences thrilled us so much that we lived them all through ourselves.
Lili had great fire and temperament, and it was a constant joy to be with her. Her merry
eyes sparkled and her curls were always flying. We lived in this happy companionship,
perfectly unconscious that our blissful life could ever change."
"But just before we were twelve years old, my father said one day that Mr. Blank was
going to leave the factory and return home. These words were such a blow, that I could
hardly comprehend them at first. They made such an impression on me, that I remember
the exact spot where my father told me. All I could understand was that Mr. Blank had
been misinformed about the business in the beginning and was obliged to give it up after a
severe loss. My father was much grieved, and said that a great wrong had been done to
Lili's father by his dishonest agents. He had lost his whole fortune as a result."
"I was quite crushed by the thought of losing Lili, and by her changed circumstances
besides. It made me so unhappy that I remember being melancholy for a long, long time
after. The following day, Lili came to say goodbye, and we both cried bitterly, quite sure of
not being able to endure the grief of our separation. We swore eternal friendship to each
other, and decided to do everything in our power to meet as often as possible. Finally, we
sat down to compose a poem together, something we had frequently done before. We cut
the verses through in the middle—we had written it for that purpose—and each took a half.
We promised to keep this half as a firm bond, and if we met again, to join it together as a
sign of our friendship."
"Lili left, and we wrote to each other with great diligence and warm affection for many
years. These letters proved the only consolation to me in my lonely, monotonous life in the
country. When we were young girls of about sixteen or seventeen, Lili wrote to me that her
father had decided to emigrate to America. She promised to write to me as soon as they
got settled there, but from then on, I never heard another word. Whether the letters were
lost, or Lili did not write because her family did not settle definitely anywhere, I cannot
say. Possibly she thought our lives had drifted too far apart to keep up our intercourse.
Perhaps Lili is dead. She may have died soon after her last letter—all this is possible. I
mourned long years for my unforgettable and dearest friend to whom I owed so much. All
my inquiries and my attempts to trace her were in vain. I never found out anything about
her."
The mother was silent and a sad expression had spread over her features, while the
children also were quite depressed by the melancholy end of the story.
One after the other said, sighing, "Oh, what a shame, what a shame!"
But little Hun, who had listened most attentively, had drawn tenderly near his mother and
said comfortingly, "Don't be sad, mamma! As soon as I am big, I'll go to America and fetch
Lili home to you."
Rolf and Willi had also joined the other listeners, and after thoughtfully gazing at a slip of
paper in his hand, Rolf asked, "Mamma, did the poem you cut apart look like a Rebus,
written on a narrow paper?"
"Perhaps, Rolf. It might have given that impression," replied the mother. "Why do you
ask?"
"Look, mamma," said Rolf, holding out the yellowish slip of paper, "don't you think this
might be your half?"
"Rolf, it really is," cried the mother, agitated. "I thought I had lost it for good, for after
keeping it many years, I suddenly could not find it. I have never really thought about it, till
I told you about this friendship. Where did you find this dear token, Rolf?"
"We found it!" cried Willi and Lili simultaneously. "We found it in the old family Bible. We
wanted to see if Eve's face was still scratched up," the twins continued, taking turns giving
their information.
"Oh, yes, that brings back another memory of Lili," said the mother with a smile. "She did
this one day as we were both imagining how beautiful it would be to be in paradise. She
suddenly grew so furious at Eve for having eaten the apple that she scratched her face in
the picture with a pencil for punishment. But my old poem! I am afraid I can't puzzle it out
any more," said the mother after trying to study the broken sentences. "It is so dreadfully
long ago. Just think, children, over thirty years!"
The mother laid the paper, carefully folded, in her workbasket and asked the children to
pick up their things and follow her, as it would soon be time for supper. As they knew well
that their papa was always punctual, they quickly packed up their things and one after the
other disappeared into the house through the triumphal arch, which had been left
standing.
Dora had been watching the quiet group under the apple tree for quite a while through the
hole in the hedge. As everybody got up and slowly went away, she had the chance to
examine one child after another. When they were all gone, Dora heaved a deep sigh and
said to herself, "If only I could be allowed to go over there, just once."
At supper, Aunt Ninette said, "At last, we have had a few quiet hours! What a relief! If this
keeps on, we might possibly remain here. What do you think, dear Titus?"
Dora waited anxiously for her uncle's answer.
"The air is very heavy in these rooms, and I feel even more dizzy than I did in Karlsruhe,"
declared the uncle.
Dora dropped her eyes to her plate and her appetite was gone.
The aunt broke out into loud wails now. Should the whole journey and their stay here
prove absolutely useless after all? Should they have moved the very first day? She found
consolation at last in the thought that the family opposite had quieted down, and that the
windows could be opened by tomorrow. Dora clung to this hope, for as long as she lived so
near, a possibility remained that she might go and play, at least a single time, with the
children in their fragrant garden.
CHAPTER V
BEFORE AND AFTER THE DELUGE
IT HAPPENED quite often that nobody had time to play with little Hun, and he himself
found nothing on earth to do. At such times, he would wander aimlessly all through the
house, bothering everyone at their work. His mother always sent him to his little table and
wanted him to keep busy there. The boy would then be very unhappy and troublesome. He
often chose the most inconvenient moments for these restless moods, when everybody
was especially busy.
The day following the events just related was a Saturday, when the house was being
cleaned and the furniture blocked all the hallways. Hun wandered about among the chairs
and sofas and seemed in just as unsettled a state as was the house.
After looking for his mother everywhere, he succeeded in finding her on the top floor of the
house, sorting the clean laundry, but she sent him downstairs again with the words, "I am
very busy now, Hun. Go and look for Paula; she may have time for you." He found Paula at
the piano.
"Go away, Hun! I have to practise and can't guess your stupid charades," she said to her
little brother, who had caught the fatal fever from Rolf. He was most anxious to say his
own charade about the nutcracker and was terribly disappointed not to have the chance.
"Here's Miss Hanenwinkel, go to her," said Paula.
"Miss Hanenwinkel, my first one cannot drink, but eat," the little one cried as soon as he
saw the governess.
"No, Hun, please spare me," the governess hurriedly interrupted him. "I do not know what
will happen if you begin it, too. I have no time. Look, Mr. Jul is just getting down from his
horse over there; go to him."
"COME, I'LL SAY IT AND YOU MUST LEARN IT BY HEART."
The little one wandered off.
"Jul, nobody wants to guess my riddles, Miss Hanenwinkel least of all," he complained to
his big brother. "She said you ought to do it."
"Did she say so? All right, then, say it," Jul encouraged him.
"My first you can't drink, but eat," began Hun, and stopped.
"All right, keep on, Hun!"
"You have to make the rest, Jul; but the whole must be nutcracker," said the little boy.
"I can see that quite clearly; but because Miss Hanenwinkel has sent me a riddle to guess
through you, I'll send her one, too. Come, I'll say it and you must learn it by heart. Then
you can go and ask Miss Hanenwinkel to solve it for you."
Standing the little one in front of him, Jul said several times quite slowly:
"When like my first Hun's crow, disturbs all men

Into the second does the whole put then
The naughty culprit, saying, 'See you again.'" *
Before very long, the small boy had memorized the lines and eagerly ran off to serve them
up to the governess.
The latter sat in the schoolroom, trying to explain a problem in arithmetic to the twins.
This proved a hard task today. The two were dreadfully absent-minded. Just then Hun
came into the room.
"A charade, Miss Hanenwinkel," he announced at once.
* Hanenwinkel translated into English means Rooster-corner.
"But I won't let you say it now. This is no time for such nonsense," said the governess,
firmly. But as Jul was the originator this time, the little boy grew quite audacious. Without
swerving, he declared several times:
"It's Jul's charade, Jul made it up."
"Then say it quickly," said the governess, visibly relenting. The boy distinctly recited his
riddle.
Miss Hanenwinkel, who came from Bremen, did not like to be left behind and was always
quick in replies. Immediately sitting down at the table, she took up pen and paper and
wrote:
"My first's the time for nuts, my whole then finds

Much pleasure in them, for at once he grinds
Them up between his teeth; but we can't see,
That there's much of my second in this. For he,
My whole, that is, throws shells upon the floor
And makes us tumble on them at the door."
"Take this to Mr. Jul," she said, giving the little one the paper, "and tell him I refuse to be
beaten. As long as he has turned my name so nicely into a charade, I am sending him one,
too. But don't come in again, Hun. We must work hard, and another disturbance might be
fatal."
Willi and Lili were less afraid of a disturbance, and it was quite visible that the recent
interruption had already had the dreaded effect. While the governess had been talking to
their brother, the twins had moved their heads closer and closer together, apparently deep
in making plans. These had proved so absorbing that they could not even remember the
simplest sums, and Miss Hanenwinkel found herself obliged to shut her book with a deep
sigh. She remarked in conclusion, that if each number represented some foolish exploit,
Willi and Lili would grasp them all.
This opinion of the governess was not without foundation, because the twins seemed
especially gifted for such exploits. Apparently a scheme of this kind was in their heads
now, and as soon as the lesson was done, they rushed enterprisingly towards the laundry.
Here they had a secret consultation opposite all the washtubs in the place.
At table, Jul pulled out a sheet of paper and asked, "Who can guess a fine riddle Miss
Hanenwinkel has composed?" After which he read it.
He was hardly finished when Rolf cried out the answer, "Julius and by rights Yule-use."
It was the right solution. Miss Hanenwinkel, however, did not read her riddle, because she
did not wish to have her peculiarity discussed and laughed at.
After dinner, Willi and Lili ran to the laundry again, for it was Saturday afternoon and they
were free to do what they pleased. Miss Hanenwinkel had meant to watch the children, but
seeing them enter the laundry, she supposed they were going to wash some doll's
clothing, a favorite occupation of theirs. She was glad they had found something to keep
them busy for at least a couple of hours.
But Willi and Lili had an idea which reached far beyond a mere doll wash. While playing
with their new Noah's ark they had entered so deeply into the miraculous existence of the
people and animals in the ark that Lili conceived the brilliant idea of executing a trip in the
ark themselves. She carefully thought out everything necessary for such a journey, and
being alert and practical, she knew quite well how to do it.
Among the washtubs, the twins selected one of medium size for the ark, one just big
enough to hold them and the animals if everybody kept nice and quiet.
Schnurri and Philomele were to represent the animals in the ark, and the first thing the
children did, was catch hold of the two pets so necessary to their idea. Schnurri followed
the call with a growl, while Philomele rubbed her soft fur against Lili's legs so caressingly
that the little girl picked her up tenderly saying, "You really are much nicer than Schnurri,
dear Philomele."
Philomele had gotten her name because she mewed very melodiously, and Schnurri his,
because he grunted and growled so much. But there was a cause for this. The two had
been commanded to live in harmony together and to do each other no harm. Schnurri
punctually obeyed these instructions by always being peaceful and considerate towards
Philomele. While they were having dinner from the same dish, he ate very slowly, knowing
that the cat with her tiny mouth could not eat as fast, as he. Philomele was always
pleasant towards the dog when anyone was watching, but when nobody was around, she
frequently lifted her paw and gave him a treacherous blow behind the ear. This would
make Schnurri growl, and as this happened very often, he growled nearly all the time. He
had gotten his name unjustly, because he was by nature a peace-loving and friendly
creature.
For the trip in the ark, some water was necessary. Lili knew that on wash days a long
wooden funnel or pipe was laid under the fountain outside and into the tub, which made
the latter fill with water. She had planned to let the water flow from the wooden funnel to
the floor of the laundry where the washtub always stood. In that way the floor would be
gradually covered with water and finally the tub would be lifted up, representing the
swimming ark. All this was carefully planned, and only the long funnel which was
necessary for that manoeuvre had to be secured.
Willi and Lili could not quite decide whether it was wiser to ask Battist or Trine for help.
Old Battist and young Trine stood in practically the same relationship as Schnurri and
Philomele. Battist had served many years in the household, and knowing about everything,
had a word to say about all the management of the house and stable, as well as the
garden and the fields. The universal respect shown to the old man annoyed Trine, who felt
that regard was due to her, too. If she had not served the family very long yet, her aunt
had lived in the Birkenfeld household so many years that she had actually become too old
to work and was resting from her labors now. Trine had taken her place and was decidedly
jealous of old Battist's authority, which she herself did not recognize at all. She behaved
very decently to the old man before the family, but teased him as soon as they turned
their backs, just as Philomele did with Schnurri.
The children knew this, and often made use of this state of affairs for their own private
ends. Willi and Lili felt that Trine would be more willing to lend them aid than the old
gardener, who never much approved of extraordinary schemes. But the needed funnel
came under his especial sceptre, and therefore Lili decided to ask the old man's assistance,
while Willi held on to Schnurri and the cat. Finding Battist on the threshing-floor sorting
out seeds, Lili stood herself in front of him with her hands back of her, taking the identical
attitude her father always took when talking with his workmen.
"Battist," she began energetically, "where is the funnel which is used in the laundry for
filling the washtubs with water?"
Battist looked at Lili from his seeds, as if anxious to weigh her question. Then he asked
deliberately, "Did your mamma send you here?"
"No, she didn't send me, I want it myself," explained Lili.
"I see; then I don't know where the funnel is," retorted Battist.
"But Battist," Lili commenced again, "I only want a little water from the spring fountain.
Why can't I have it?"
"I know you two small birds," growled Battist. "Once a little bit of fire and then a little bit
of water, and finally some dreadful mishap. You can't have it this time, you can't have it."
"Then I don't care," sulked Lili, and went at once to the kitchen where Trine was sweeping
the floor.
"Trine," said the little girl pleasantly, "won't you come and give us the funnel for the
fountain? Battist is horrid, he won't even give it to us for a second. But you will let us have
it, won't you, Trine?"
"Of course," replied Trine. "I don't see why you shouldn't have a little bit of water. But
you'll have to wait until the old bear goes away. Then I'll go with you."
After a while Trine saw Battist walking across the yard towards the fields.
"Come, now," she said, taking Lili's hand in hers and running to the laundry.
She pulled out the pipe from its hiding place, laid one end under the spigot and the other
into a small tub. Then she explained to Lili how to take the pipe away when the bucket was
full enough. She and Willi could do this quite well themselves and when they needed more
water they could put it back. Trine had to go back to her work now.
When the maid left, they were ready to start on their excursion. After the pipe was laid on
the floor, Lili climbed in, followed by Willi, and Philomele was lifted and Schnurri was pulled
inside. Noah and his wife sat in their beautiful ark now, grateful over their delivery and
joyful over their trip on the rising floods. The water from the fountain was steadily flowing
into the laundry, and all of a sudden the ark was lifted and began to float. Noah and his
wife screamed with delight. They had really succeeded in their plans, the ark actually
swam about on real waves.
Several high stone steps led down into the laundry, and it therefore held a large quantity
of water. The water rose steadily higher and higher, and the children began to feel a little
frightened.
"Look, Willi, we won't be able to get out any more," said Lili, "it's getting higher all the
time."
Willi looked out thoughtfully over the edge of the tub and said, "If it gets much higher,
we'll have to drown."
Of course it kept on getting higher and higher.
Schnurri was beginning to get restless, too, and by jumping about, threatened to upset the
washtub. It rocked violently to and fro. The water by that time was so deep that the
children could not possibly climb out again, and seized by a sudden panic, they began to
shriek with all their might: "We are drowning, we are drowning! Mamma! Mamma! Battist!
Trine! We are drowning!"
Finally, instead of words, they just frantically screeched and yelled. Schnurri barked and
growled from sympathy, while Philomele revealed her true character, and began to bite and
scratch, while meowing loudly. Philomele refused to go into the water, neither would she
stay in the tub. Instead, she went on crazily and scratched the children whenever she
could. But when the faithful Schnurri saw that no assistance was coming in answer to their
cries, he jumped into the water with a big leap. He swam towards the door, gave himself a
shake and ran away. But the children yelled worse than ever now, for Schnurri had nearly
upset the tub in jumping out.
Dora had long ago run down to her hole in the hedge to see what was the cause of the
pitiful cries.
The laundry stood close to the hedge, but she could see nothing but a funnel through
which water flowed into the laundry. But she heard their cries about drowning and turning
about, she ran upstairs again.
"Aunt Ninette," she cried breathlessly, "two children are drowning over there. Don't you
hear them, don't you hear them?"
The aunt had heard the yells, despite her tightly barred windows.
"Oh, gracious, what does it mean?" cried the affrighted aunt. "Of course, I heard the awful
noise, but who is drowning, I wonder? Mrs. Kurd! Mrs. Kurd! Mrs. Kurd!" Meanwhile, the
soaked dog ran in big leaps towards the coachhouse, where Battist was cutting bean poles.
Schnurri rushed up to him, pulled his trousers, barked violently, then tried to pull Battist
along again, howling incessantly.
"Something is up," said Battist, and putting one of the poles on his shoulder, he said to
himself, "One can never tell what may be useful."
Herewith, he followed Schnurri, who gaily preceded him to the washhouse. By that time,
the mother, the governess, Paula, Rolf and Hun, and at last Trine had assembled, as the
awful noise had penetrated into every nook and corner of the house and garden. Battist at
once held his long pole out over the floods towards the tub.
"Take hold of it tight and don't let it go!" he called to the children, and after drawing the
whole ark towards him, he lifted the inmates onto dry land.
Willi and Lili were so scared and white that they had to recover a little before being
examined about their exploit. Taking each by the hand, their mother led them to the bench
under the apple tree and gave them a chance to revive a little.
Jul, leading the small Hun by the hand, followed and said, "Oh, you terrible twins, some
day you will both come to a terrible end."
With trousers turned up, old Battist had stepped into the deluge, and had opened all the
vents for draining to let the floods disperse. To Trine, who stood beside him, he said
pityingly, "It only happened because you have no more sense than the seven-year-olds!"
He knew quite well who had fetched the funnel. Trine, realizing that she had been duped,
could give no answer, but like Philomele, got ready to scratch her adversary.
When everybody sat safe and sound again under the apple tree, Philomele came up to Lili,
tenderly meowing and rubbing against the girl's legs. But the child pushed her away, and
instead she and Willi tenderly stroked the wet Schnurri, who lay at their feet on the
ground. The twins secretly resolved to give Schnurri their whole supper that night, for in
their great extremity, they had found out the true character of their pets.
After thoughtfully gazing at the rescued twins for a while, the small Hun joined Jul, who
was wandering to and fro on the gravel path.
"Jul," said the little one solemnly, "tell me in what way the terrible twins could come to a
fearful end?"
"They might do it in different ways, Hun," replied Jul, standing still. "You see they have
already tried fire and water. In some excited mood, they may next pull down the house
over our heads. Then we'll all be lying underneath, and everything will be over."
"Can't we quickly jump away?" asked little Hun, concerned.
"We can, if they don't do it in the middle of the night."
"Please wake me up then," Hun implored his brother.
Mrs. Kurd had come in answer to Aunt Ninette's repeated cries at the identical moment
when Battist was pulling the ark to safety and the cries had stopped.
"Did you hear it, Mrs. Kurd? Wasn't it terrible? But everything is quiet now. Do you
suppose they were saved?"
"Of course," said Mrs. Kurd calmly. "The little ones were just screaming a little, and there
can't have been any real danger."

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Cold Micro Metal Forming: Research

Report of the Collaborative Research

Biota Grow 2C gather 2C cook Loucas

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Materials Forming, Machining and Post Processing Kapil

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LNPE publishes authored conference proceedings, contributed volumes and

More information about this series at http://www.springer.com/series/10642

Bernd Kuhfuß Peter Maaß

Claus Thomy Hans-Werner Zoch

Cold Micro Metal Forming

Bernd Kuhfuß Peter Maaß

Claus Thomy Hans-Werner Zoch

ISSN 2194-0525 ISSN 2194-0533 (electronic)

A prerequisite for successful cooperation is the funding of manpower and

Bremen, Germany Frank Vollertsen

1 Introduction to Collaborative Research Center Micro Cold

6 Materials for Micro Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Mostafa Agour BIAS—Bremer Institut für angewandte Strahltechnik GmbH,

Sybille Friedrich BIAS—Bremer Institut für angewandte Strahltechnik GmbH,

Ann-Kathrin Onken Bremen Institute for Mechanical Engineering (bime),

Frank Vollertsen Faculty of Production Engineering-Production Engineering

Frank Vollertsen, Sybille Friedrich, Claus Thomy,

Frank Vollertsen*, Sybille Friedrich and Claus Thomy

F. Vollertsen (&) S. Friedrich C. Thomy R. B. Bergmann (&)

© The Author(s) 2020 1

IVAM Microtechnology Network, medical technology is by far the most important

1.2 Aim of the SFB 747

1.3 Structure and Partners

Frank Vollertsen* and Sybille Friedrich

Fig. 1.1 Perspectives of the

Materials Friction polishing Tools

Material accumulation Micro forming Material displacement

Component strength Simultaneous Engineering

Quality control and characterization Process design

Colloquium Micro Production Int. Conference on New Forming Technology

Industrial meetings Int. Conference on Technology of Plasticity

Trade Fair for Production in the North Hannover Trade Fair

1. period 2. period 3. period

New processes and Improve complexity Upscaling the number

2007-2010 2011-2014 2015-2018

Fig. 1.4 Funding periods and their main research focus

innovation process production

Collaboration Research Center “Micro Cold Forming” concerning mastering these

1.4 Main Results

1.4.1 Innovation Speed

1.4.1.1 Process Design

Ann-Kathrin Onken and Kirsten Tracht*

1.4.1.2 Design of Production Systems

Ann-Kathrin Onken and Kirsten Tracht*

1.4.2 Micro Mass Forming

Florian Böhmermann* and Oltmann Riemer*

Subsequent dry micro rotary swaging experiments against aluminum workpieces

"Beautiful, beautiful! I suppose Rolf is the originator of this?"