SFB 666: Integral Sheet Metal Design with Higher Order Bifurcations - Development, Production, Evaluation
Materials Science and Engineering
Mathematics
Final Report Abstract
Finding technical solutions for current, challenging problems is one of the most important driving factors for creating innovations. The design tasks are particularly demanding, if not only sufficient but also the best possible solutions are to be worked out taking into account all relevant boundary conditions and requirements. Product development methods that have been applied so far neglect a particularly important driver for product developments to a large extent: manufacturing technologies. On the basis of numerous case studies, the CRC 666 has shown that manufacturing knowledge is extremely important for product development in order to find the best technical solutions. However, this knowledge is generally not available to the product designers in a usable form. Therefore, many possibilities for utilizing manufacturing-induced properties are not exhausted. Starting from the novel methods of linear flow splitting and combinations with known manufacturing technologies, fascinating design possibilities for sheet metal products could be systematically developed within the work of the CRC 666. Thus, the overall goal of the CRC 666 was fully achieved: the creation of a consistently formalized approach to exploit the technological potential of new processes for an optimized product design. Within the funding periods of the SFB 666, a new approach for an integrated algorithm-based product and process development was gradually developed which now allows a comprehensive view of product and process information using mathematical algorithms for the first time. For the aimed integral production of thin-walled, branched structures made of high-strength and ultra-highstrength sheet metal without a material doubling in a continuous flow production at room temperature, extensive process and method developments as well as validations were carried out in the CRC 666. Successfully, the process potentials of the rolling processes of linear flow splitting and linear bend splitting have been developed and combined with cutting and bending processes to completely new design possibilities for profile components. This also includes durable and reversible profile connections in which the high-strengthened branched areas were specifically positioned in the connection zones. Starting from the mechanisms of linear flow splitting, important knowledge into severe plastic deformation (SPD) methods have been developed in material-scientific research. In particular, the coupling with investigations on the operational and rolling strength, allowed to quantify the advantageous property changes by the highly plastic deformation. The flexible linear flow splitting developed within the CRC 666 represents a manufacturing technology which is outstanding in terms of its product and process flexibility. Within the individual funding periods the work of the CRC 666 was followed by a research roadmap that has been designed with increasing demands on geometric complexity, optimized functionalities and modeling depth. Numerous scientists working in the CRC 666 have been able to further improve their scientific qualifications by means of challenging and interdisciplinary tasks. Today, they occupy challenging positions in business and science. All scientific findings of the CRC were documented in a joint book publication.
Publications
- Herstellung einteilig verzweigter Blechstrukturen. Werkstattstechnik Online. 2005
Groche, Peter; Vucic, Dragoslav
- Flexible Prozessketten für Mehrkammerprofile aus Blech. Werkstattstechnik Online. 2006
Groche, Peter; Ringler, Jens; Walter, Martin; Munirathnam, Madhu
- Zyklisches Werkstoffverhalten sprühkompaktierter Aluminiumwerkstoffe. Kennwerte für die Bauteilbemessung: Von der Probe zum Bauteil. Materialwissenschaft und Werkstofftechnik. 2006
Landersheim, Volker; el Dsoki, Chalid; Bruder, Enrico; Bohn, Tilman; Müller, Clemens
(See online at https://doi.org/10.1002/mawe.200600091) - Severe plastic deformation by linear flow splitting. Materialwissenschaft und Werkstofftechnik. 2007
Müller, Clemens; Bohn, Tilman; Bruder, Enrico; Bruder, Thomas; Landersheim, Volker; el Dsoki, Chalid; Groche, Peter; Veleva, Desislava
(See online at https://doi.org/10.1002/mawe.200700210) - Ultra-HSC-Bearbeitung von Bandkanten. Werkstattstechnik Online. 2007
Abele, Eberhard; Stein, Sebastian; Munirathnam, Madhu
- Formation of ultrafine-grained microstructure in HSLA steel profiles by linear flow splitting. Journal of Materials Science. 2008
Bohn, Tilman; Bruder, Enrico; Müller, Clemens
(See online at https://doi.org/10.1007/s10853-008-2682-2) - Numerical fatigue strength evaluation of inhomogeneous, linear flow split profiles. Proceedings of the ASME 2008 International Design Engineering Technical Conferences & Computers and Information in Engineering Conference 2008
Landersheim, Volker; el Dsoki, Chalid; Hanselka, Holger; Bruder, Enrico; Veleva, Desislava; Groche, Peter; Bohn, Tilman; Müller, Clemens; Nieslony, Adam
(See online at https://dx.doi.org/10.1115/DETC2008-49737) - Severe Plastic Deformation (SPD) Processes for Metals. CIRP Annals - Manufacturing Technology. 2008
Azushima, A.; Kopp, R.; Korhonen, A.; Yang, D. Y.; Micari, F.; Lahoti, G. D.; Groche, P.; Yanagimoto, J.; Tsuji, N.; Rosochowski, A.; Yanagida, A.
(See online at https://dx.doi.org/10.1016/j.cirp.2008.09.005) - Analyse der Wirkung von Kerben, Mittel- und Eigenspannungen auf die Schwingfestigkeit des hochumgeformten Werkstoffbereichs von Spaltprofilen. Materialwissenschaft und Werkstofftechnik. 2009
Landersheim, Volker; Eigenmann, Bernd; el Dsoki, Chalid; Bruder, Thomas; Sonsino, Cetin Morris; Hanselka, Holger
(See online at https://doi.org/10.1002/mawe.200900520) - Bending-Rolling combinations for strips with optimized cross section geometries. CIRP Annals - Manufacturing Technology. 2009
Groche, Peter; Ringler, Jens; Abu Schreehah, Tareq
(See online at https://doi.org/10.1016/j.cirp.2009.03.051) - Influence of sputter rate and crystal orientation on the distribution of carbon in polycrystalline copper surfaces treated by plasma immersion ion implantation. Journal of Applied Physics. 106 2009
Flege, S.; Kraft, G.; Bruder, E.; Baba, K.; Hatada, R.; Ensinger, W.
(See online at https://dx.doi.org/10.1063/1.3176488) - Standwegsteigerung bei der Bandkantenbearbeitung. Werkstattstechnik Online. 2009
Abele, Eberhard; Stein, Sebastian
- Three-dimensional kernel development with parasolid for integral sheet metal design with higher order bifurcations. Proceedings of the ASME 2009 International Design Engineering Technical Conferences & Computers and Information in Engineering Conference 2009
Rollmann, Thomas H.; Schüle, Anselm L.; Anderl, Reiner; Chahadi, Youssef
(See online at https://dx.doi.org/10.1115/DETC2009-86546) - Combination of an Adaptive Multilevel SQP Method and a Space-Time Adaptive PDAE Solver for Optimal Control Problems. Procedia Computer Science. 2010
Clever, Debora; Lang, Jens; Ulbrich, Stefan; Ziems, J. Carsten
(See online at https://doi.org/10.1016/j.procs.2010.04.159) - Estimation of the essential supremum of a regression function. Statistics & Probability Letters. 2010
Kohler, Michael; Krzyzak, Adam; Walk, Harro
(See online at https://doi.org/10.1016/j.spl.2011.02.011) - Further Processing of UltraFine-Grain Materials. International Journal of Material Forming. 2010
Taplick, Christoph; Rullmann, Felix; Groche, Peter
(See online at https://doi.org/10.1007/s12289-010-0899-5) - Adaptive Multilevel Inexact SQP Methods for PDE-constrained Optimization. SIAM Journal on Optimization. 2011
Ziems, Jan; Ulbrich, Stefan
(See online at https://doi.org/10.1137/080743160) - High strength hydroformed steel profiles with free flanges. Steel research international. 2011
Taplick, Christoph; Schmitt, Wolfram; Rullmann, Felix; Ludwig, Christian; Groche, Peter
- An object-oriented information model for the representation of free form sheet metal parts in integral style. Tools and Methods of Competitive Engineering. 2012
Weitzmann, Oliver J.; Schüle, Anselm L.; Rollmann, Thomas H.; Anderl, Reiner; Göllner, Thea
- Application of the local strain approach on a rolling point contact model. International Journal of Fatigue. 2012
Karin, Ivan; Tomasella, Alessio; Landersheim, Volker; Kaufmann, Heinz; Hanselka, Holger
(See online at https://doi.org/10.1016/j.ijfatigue.2012.09.020) - Definition of a Tool Library for the Approximation of Freeform Surfaces. Advanced Materials Research. 2012
Schäfer, Stefan; Reising, Jakob; Abedini, Scholeh; Bäcker, Frederic
(See online at https://doi.org/10.4028/www.scientific.net/AMR.875-877.841 https://doi.org/10.4028/www.scientific.net/AMR.875-877.841 https://doi.org/10.4028/www.scientific.net/AMR.875-877.841) - Integration of manufacturing-induced properties in product design. CIRP Annals - Manufacturing Technology. 2012
Groche, Peter; Schmitt, Wolfram; Bohn, Andrea; Gramlich, Sebastian; Ulbrich, Stefan; Günther, Ute
(See online at https://doi.org/10.1016/j.cirp.2012.03.041) - Sheet Metal Forming-Processes and Applications. Sheet Metal Forming-Processes and Applications. ASM International. 2012
Görtan, Okan; Livatyali, Haydar; Groche, Peter; Altan, Taylan; Tekkaya, Erman (eds.)
- The effect of deformation texture on the thermal stability of UFG HSLA steel. Journal of Materials Science. 2012
Bruder, Enrico
(See online at https://doi.org/10.1007/s10853-012-6518-8) - A Simultaneous Engineering Approach for Free Form Bifurcated Sheet Metal Products. Smart Product Engineering. Lecture Notes in Production Engineering. Springer 2013
Schüle, Anselm; Anderl, Reiner; Stark, Rainer; Abramovici, Michael (eds.)
(See online at https://doi.org/10.1007/978-3-642-30817-8_39) - Festwalzen in der Rollenfertigung. Werkstattstechnik Online. 2013
Groche, Peter; Monnerjahn, Vinzent; Steitz, Manuel; Ludwig, Christian
- Fixed design regression estimation based on real and artificial data. Journal of Nonparametric Statistics. 2013
Furer, Dmytro; Kohler, Michael
(See online at https://doi.org/10.1080/10485252.2012.749257) - Quantification of local and global elastic anisotropy in ultrafine grained gradient microstructures, produced by linear flow splitting. Materials Science and Engineering. 2013
Niehuesbernd, Jörn; Müller, Clemens; Pantleon, Wolfgang; Bruder, Enrico
(See online at https://doi.org/10.1016/j.msea.2012.09.067) - Nonparametric estimation of a conditional density. ESAIM Probability and Statistics. 2014
Bott, Ann-Kathrin; Kohler, Michael
(See online at https://doi.org/10.1007/s10463-015-0535-8) - On the Origin of Specimen: load-adapted integral sheet metal products. Procedia Engineering. 2014
Neuwirth, Manuel; Schmitt, Wolfram; Kretz, Felix; Groche, Peter
(See online at https://doi.org/10.1016/j.proeng.2014.09.169) - Metal forming beyond shaping: Predicting and setting product properties. CIRP Annals - Manufacturing Technology. 2015
Tekkaya, A. E.; Allwood, J. M.; Bariani, P. F.; Bruschi, S.; Cao, J.; Gramlich, S.; Groche, P. et al.
(See online at https://doi.org/10.1016/j.cirp.2015.05.001) - Research on the influence of the metal working of the band edge on the process of linear flow splitting. Materialwissenschaft und Werkstofftechnik. 2015
Neuwirth, Manuel; Ahmels, Laura; Schmidt, Sebastian; Hegemann, Michael; Groche, Peter; Müller, Clemens
(See online at https://doi.org/10.1002/mawe.201500449) - Technology pushed process and product innovation - Joining by Linear Flow Splitting. CIRPe 2015 - Understanding the life cycle implications of manufacturing. 2015
Wagner, Christian; Gramlich, Sebastian; Monnerjahn, Vinzent; Groche, Peter; Kloberdanz, Hermann
(See online at https://dx.doi.org/10.1016/j.procir.2015.08.065) - How to Enhance a Graphic Representation of Topological Optimized Profiles Regarding Manufacturing Information. Journal of Mechanical Engineering and Automation. 2016
Albrecht, Katharina; Anderl, Reiner
(See online at https://dx.doi.org/10.5923/j.jmea.20160602.03) - Improving the formability of linear flow split profiles by laser annealing. Materialwissenschaft und Werkstofftechnik. 2016
Niehuesbernd, Jörn; Monnerjahn, Vinzent; Bruder, Enrico; Groche, Peter; Müller, Clemens
(See online at https://doi.org/10.1002/mawe.201600577) - Information Model for the Integration of Manufacturing Restrictions into the Algorithm Based Product Development Process. Procedia CIRP. 2016
Albrecht, Katharina; Anderl, Reiner
(See online at https://doi.org/10.1016/j.procir.2016.04.136) - Preconditioners based on "Parareal" timedomain decomposition for time-dependent PDE-constrained optimization. Multiple Shooting and time domain decomposition methods. Contributions in Mathematical and Computational Sciences. 2016
Ulbrich, Stefan; Carraro, Thomas; Geiger, Michael; Körkel, Stefan; Rannacher, Rolf
(See online at https://doi.org/10.1007/978-3-319-23321-5_8) - Manufacturing Integrated Design: Sheet Metal Product and Process Innovation. Springer book 2017
Groche, Peter; Bruder, Enrico; Gramlich, Sebastian (eds.)
(See online at https://dx.doi.org/10.1007/978-3-319-52377-4) - Manufacturing-integrated product solutions: Design support between product function and manufacturing processes. Materials Science and Engineering Technology. 2017
Roos, Michael; Wagner, Christian; Weber Martins, Thiago; Albrecht, Katharina; Anderl, Reiner; Kirchner, Eckhard
(See online at https://doi.org/10.1002/mawe.201600727) - Remote joining by plastic deformation in the process of linear flow splitting. Journal of Materials Processing Technology. 2017
Groche, Peter; Monnerjahn, Vinzent; Özel, Mahmut; Yu, Yufan
(See online at https://doi.org/10.1016/j.jmatprotec.2017.03.024)
