The reliable fabrication of functional surface structures has become an important factor in modern production processes. With regard to the field of large area micro patterning, particular applications demand for economical manufacturing processes to gain advantageous surfaces. The process-integrated rolling of these structures is a promising approach if suitable roll geometries can be manufactured. This paper focuses on the large area rolling of so called riblet structures. Both experimental test series and related numerical forming simulations are taken into account. Furthermore, demands and potentials from the roll manufacturing point of view are highlighted. Above all, the feasibility of a new winding concept for the continuous patterning of rolls with small negative riblet structures is pointed out. By this means, challenging requirements in connection with riblet rolls-the realization of finest structures with sharp ground radii-can be matched.

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The continuing miniaturization of production systems and products poses a challenge for metal forming technologies to produce precise small scale products with microscopic geometric details. Thin metal plates with channel structures are considered to be typical examples for microfluidic applications [1,2]. In this study the coining process of sheet metal to produce channel and rib structures is examined in terms of geometrical die parameters and tool design. For this reason extensive experimental series and numerical simulations have been realized and evaluated.

Properties and functional behavior of modern products are strongly influenced by their surface characteristics - like their appearance and haptics as well as their optical, tribological and fluidic performance [1]. In present production processes these functional features are mostly generated by surface treatment processes (e. g. grinding, etching, coating). In contrast to these costintensive and complex off-line sequences rolling provides an opportunity to apply functional structures on sheet metal products using non-pollutive synergy-potentials of the process.

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