TRR 30: Process-integrated Manufacturing of Functionally Graded Structures Based on Coupled Thermo- mechanical Phenomena
Materials Science and Engineering
Final Report Abstract
The goal of the collaborative research center Transregio 30 (hereinafter referred to as SFB/TR TRR 30) was the establishment of basic principles for the manufacture of functionally graded structures in steel, aluminum, and plastic components in large series applications. The starting point for this aim were manufacturing processes based on thermomechanically coupled phenomena. An unrestricted combinability of product design and the property profile made up the vision that was to be transferred into reality. What made this exceptional was the aim to exclusively use mono-materials, meaning materials that are not layer systems, composite materials, or materials that have been functionally enhanced with filling materials, or the like. While performing research, the entire process chain was taken into account, from the manufacture of the raw material and material design to the preparation of the material, the shaping of it, the final processing, and the follow-up treatment. The subsequent examination of the application behavior was meant to enable deductions about the influences of the manufacturing process to be made. The required interdisciplinary linking of the component projects, which was so crucial for the success of SFB/TR TRR 30, was implemented extensively. The research studies were assigned to four project areas: “Process Design”, “Material/ Modelling / Parameter Identification / Experimental Validation”, “Numeric Treatment” and “Process-Accompanying Product Optimization”. The project results clearly show that the interdisciplinary cooperation that extended beyond the individual project areas was necessary. This was the only way to successfully describe the microstructures, their genesis, and their resulting properties, as well as the targeted functionalization. This specifically means the precise customization of product properties and their limitations set by the microstructure. The formation of work groups would not have been possible without intensive interdisciplinary collaboration between all component projects. These work groups encompass “Modelling and Simulation”, “Product-Process-Reciprocal Effect”, and “Property Characterization of Functionally Graded Materials. The same applies for the development of the technology carriers “Flanged Shaft”, “Crashbox” and “Interior Door Trim”. Moreover, the integrated research training group contributed to an extensive collaboration that transcended the boundaries of the individual disciplines. It achieved this by means of doctoral meetings, continued advanced trainings, and the industrial advisory committee, i.e., cooperations or guest lectures. Functionalization was able to be implemented in a reproducible fashion by means of creating graded structures in short process routes that can be automated, and which are combined with thermomechanically coupled process control. The following options were able to be investigated: processes suitable for large series, resource efficiency, and the combination of the product design and the property profile. Furthermore, the significant advancement of the process-technological options of the local, functional gradation, the modelling of processes and material properties, and the characterization of the structural properties were also successfully implemented. The locally differing microstructures were examined in regards to the reciprocal effects of the process, structure, and properties, in order to be able to adjust these specifically. The obligatory knowledge needed to precisely influence the microstructure of mono-materials was acquired, i.e., how to carry out and combine manufacturing processes. For example, in doing so, a new tempering concept was able to be developed while taking the material rheology in thermoplastic composite structures into account. Moreover, targeted anisotropies were able to be created in amorphous plastics using an extrusion and stretching process. The correlating modelling was carried out by component project cooperation partners. Another example of the successful collaboration between fields was the implementation of the coupling of the pre-heating, transfer, and the re-shaping of wave-shaped steel components. Here, thermo-shock processes in the molding tool were described, thermal layers were integrated, and cooling processes that took place during the transfer were observed. Additionally, the demonstrated feasibility and simulation of the combination of extrusion presses and electromagnetic shaping were achieved. On top of that, the one-step manufacturability of functional elements using friction spinning, the integration of the method in the entire process chain, and the development of combination tools for the integration of turning and shaping processes must be named. The targeted manufacture of graded component properties by means of processing procedures suitable for large series shifted the focus to the robustness of methods, processes, and graded structures. A personal definition of the term robustness was developed in order to be able to make precise statements about the employed methods and processes. The description of the properties and processes was ultimately achieved by coupling so-called “empirical” and “physical” models. Please reference the reports of the first and second funding periods for further information.
Publications
- (2008): Bearbeitungseigenspannungen durch Drehen thermo-mechanisch umgeformter Flanschwellen aus dem Werkstoff 51CrV4. HTM - Journal of Heat Treatment and Material, 63 (2008) 5, S. 245-251
Biermann, D., Grüning, A., Grünert, S. Scholtes, B., Zabel, A.
(See online at https://doi.org/10.1515/htm-2008-0002) - (2009): Functionally Graded Materials in Industrial Mass Production, Verlag Wissenschaftliche Scripten, ISBN: 978-3-937524-91-7
Steinhoff K., Maier H. J., Biermann D.
- (2010): A monolithic FEM approach for the logconformation reformulation (LCR) of viscoelastic flow problems. J. Non-Newtonian Fluid Mech., Vol. 165, S. 1105-1113
Damanik, H., Hron, J., Ouazzi, A., Turek, S.
(See online at https://doi.org/10.1016/j.jnnfm.2010.05.008) - (2010): Cyclic stress-strain behavior and damage of tool steel AISI H11 under isothermal and thermal fatigue conditions. Mat. Science and Engineering A527, S. 1979 – 1985
Grüning, A., Lebsanft, M., Scholtes, B.
(See online at https://doi.org/10.1016/j.msea.2009.11.031) - (2010): Development and testing of a new pressure cell for rheological characterization of polymer melts. Applied Rheology, 20:2, 23229
Krebs, M., Wünsch, O.
(See online at https://doi.org/10.3933/applrheol-20-23229) - (2011): Functional Gradation Produced by Differential Thermo-Mechanical Processing. In: Hirt, G.; Tekkaya, A.E. (Edtrs.): Steel Research International. Special Edition: 10th International Conference on Technology of Plasticity, ICTP 2011, Düsseldorf (D): Verlag Stahleisen GmbH, 2011, pp. 944-949
Saba, N., Fuß, D., Weidig, U., Steinhoff K.
- (2011): Thermo-mechanical processing of aluminum profiles by integrated electromagnetic compression subsequent to hot extrusion. Journal of Materials Processing Technology 211, 5, Special Issue: Impulse Forming, S. 936-943
Jäger, A., Risch, D., Tekkaya, A.E.
(See online at https://doi.org/10.1016/j.jmatprotec.2010.06.016) - (2012): Diffraction Residual Stress Analysis in Technical Components - Status and Prospects. Thin Solid Films 530, S. 53 – 61
Manns Th., Scholtes, B.
(See online at https://doi.org/10.1016/j.tsf.2012.03.064) - (2012): Evaluation of preheating strategies improving the mechanical properties in intermediate areas of functionally graded materials. In: Heim, H.-P.; Biermann, D.; Maier, H. M. (Edtrs.): Proceedings of the 1st International Conference on Thermo-Mechanically Graded Materials, Kassel (D): Verlag Wissenschaftliche Scripten, 2012, pp. 85-90
Fuß, D., Clobes, J., Weidig, U., Steinhoff, K.
- (2012): In situ characterization of backstress effects on the austenite-to-bainite phase transformation. Scripta Materialia 67 (2012) 368-371
Holzweissig, M.J., Canadinc, D., Maier, H.J.
(See online at https://doi.org/10.1016/j.scriptamat.2012.05.027) - (2012): Influence of a fracture mechanical gradation on crack propagation. 1st International Conference on Thermomechanically Graded Materials, 29.10., Kassel (Germany), ISBN 978-3-942267-58-8, S. 169-174
Schramm, B., Richard, H.A., Steigemann, M., Specovius-Neugebauer, M.
- (2012): Manufacturing of Self-Reinforced All-PP Composites. In: Bhattacharyya, D; Stoyko, F. (Hrsg.), Synthetic Polymer-Polymer Composites. Carl Hanser Verlag, Munich, S. 719-738
Bledzki, A. K., Heim, H.-P., Paßmann, D., Ries, A.
(See online at https://doi.org/10.3139/9781569905258.022) - (2012): Monolithic Newton-multigrid solution techniques for incompressible nonlinear flow models. Int. J. Numer. Meth. Fluids, Vol. 71, Issue 2, S. 208-222
Damanik, H., Hron, J., Ouazzi, A., Turek, S.
(See online at https://doi.org/10.1002/fld.3656) - (2012): Multi-phase transformations at large strains - Thermodynamic framework and simulation, Int. J. Plast. 39, S. 1-26
Mahnken, R., Wolff, M., Schneidt, A., Böhm, M.
(See online at https://doi.org/10.1016/j.ijplas.2012.05.009) - (2012): Scharnierelement, hergestellt auf Basis mindestens eines Flächengebildes und Verfahren zur Herstellung eines Scharnierelements auf Basis mindestens eines Flächengebildes. Patent: DE 10 2011 110 937.8
Heim, H.-P., Ries, A.. Lieven, N., Sennhenn, D.
- (2012): Some new aspects of the invariants of the rate deformation tensor and their application on viscoelastic polymer melts, Technische Mechanik, 32-6, S. 667-683
Al-Baldawi, A., Wünsch, O.
- (2013): An Innovative Incremental Forming Process for the Manufacturing of Functional Graded Parts. Key Engineering Materials 554-557, S. 1368-1374
Homberg, W., Lossen, B., Struwe, A.
- (2013): Experimental investigations on the induced anisotropy of mechanical properties in polycarbonate films. In: ISRN Materials Science Schramm, B., Richard, H.A., Steigemann, M., Specovius-Neugebauer, M. (2012): Influence of a fracture mechanical gradation on crack propagation. 1st International Conference on Thermomechanically Graded Materials, 29.10., Kassel (Germany), ISBN 978-3-942267-58-8, S. 169-174
Schöppner, V., Wibbeke, A., Mahnken, R.
(See online at https://doi.org/10.1155/2013/649043) - (2013): Functionally Graded Materials in Industrial Mass Production, Vol.2, Verlag Wissenschaftliche Scripten, ISBN: 978-3-942267-91-5
Heim H.-P., Biermann D., Homberg W.
- (2013): Influence of bias voltage on residual stresses and tribological properties of TiAlVN-coatings at elevated temperatures. In: Taiwan Association for Coating and Thin Film Technology (TACT 2011) 231, S. 122–125
Tillmann, W., Sprute, T., Hoffmann, F., Yin-Yu, C., Ching-Yu, T.
(See online at https://doi.org/10.1016/j.surfcoat.2012.03.012) - (2013): Phenomenological Process Simulation and Multiscale Tool Simulation directed to a Hybrid Forming Process, Dissertation, Paderborn, Shaker-Verlag Band 2013, 6, ISBN: 978-38440-1918-6
Sauerland, K.-H.
- (2013): Planning and Optimisation of Manufacturing Process Chains for Functionally Graded Components — Part 1: Methodological Foundations Production Engineering — Research and Development, 7 (2013) 6, S. 657-664
Biermann, D., Gausemeier, J., Hess, S., Petersen, M., Wagner, T.
(See online at https://doi.org/10.1007/s11740-013-0490-2) - (2013): Precise computation and error control of stress intensity factors and certain integral characteristics in anisotropic inhomogeneous materials. International Journal of Fracture 182, S. 67-91
Steigemann, M., Schramm, B.
(See online at https://doi.org/10.1007/s10704-013-9859-7) - (2013): Preconditioning for modal discontinuous Galerkin methods for unsteady 3D Navier-Stokes equations. Journal of Computational Physics, 240, S. 20-35
Birken, P., Gassner, G., Haas, M., Munz, C.-D.
(See online at https://doi.org/10.1016/j.jcp.2013.01.004) - (2013): Simulation based microstructural optimization of thermo-mechanically treated steel components. In: Materials Science and Engineering Technology, Weinheim (D): Wiley-VCH, Vol. 44 – No. 12, 2013, pp. 977-984
Stein, T., Fuss, D., Grahlmann, P., Luetje, M., Brueckner-Foit, A., Steinhoff, K., Weidig, U.
(See online at https://doi.org/10.1002/mawe.201300158) - (2013): Verfahren zur Herstellung von Werkzeugspulen und/oder Werkzeugen für die Magnetumformung insbesondere dünnwandiger Werkstücke aus elektrisch leitfähigen Werkstoffen sowie entsprechend hergestellte Werkzeugspule. DE 10 2013 013 335.1
Jäger, A., Hölker, R., Lueg-Althoff, J., Kwiatkowski, L., Demir, O. K., Tekkaya, A. E.
- (2013): Visualisation of the Degrees of Compaction of Self-reinforced Polypropylene Composites by means of Ultrasonic Testing. Journal of Plastics Technology 9 Vol. 6, S. 275-294
Heim, H.-P., Tillmann, W., Ries, A., Sievers, N., Rohde, B., Zielke, R.
- (2014): A novel homogenization method for phase field approaches based on partial rank-one relaxation, Journal of the Mechanics and Physics of Solids, Vol. 68, 251-266, 2014
Mosler J., Schyglo O., Montazer H. Hojjat
(See online at https://doi.org/10.1016/j.jmps.2014.04.002) - (2014): Entwicklung des Herstellprozesses von eigenverstärktem Polycarbonat durch monoaxiales Recken, Band: 2014,5, Reihe: Schriftenreihe Institut für Leichtbau mit Hybridsystemen, 978-3-8440-3143-0
Wibbeke, A.
- (2014): Experimental Investigation of PC-Films Using Optical Measurements. Int. Polym. Proc., 29(2), S. 260– 271
Dammann, C., Caylak, I., Mahnken, R.
(See online at https://doi.org/10.3139/217.2848) - (2014): Friction-Spinning – Interesting approach to the manufacture of complex sheet metal parts and tubes. In: Mori, T.I.A.K.i. (Hrsg.), Procedia Engineering of the 11th ICTP Vol. 81, Elsevier, Nagoya, Japan, S. 2379-2384
Lossen, B. & Homberg, W.
(See online at https://doi.org/10.1016/j.proeng.2014.10.337) - (2014): Influence of nitriding parameters on the tribological properties and the adhesion of Ti- and Cr-based multilayer designs. In: The 41st International Conference on Metallurgical Coatings and Thin Films 260, S. 380–385
Tillmann, W., Markus, D., Sprute, T.
(See online at https://doi.org/10.1016/j.surfcoat.2014.09.017) - (2014): Journal of Materials Processing Technology: Towards the multi-scale simulation of martensitic phase-transformations: An efficient post-processing approach applied to turning processes, 2014, Volume 214
Ostwald, R., Tiffe, M., Bartel, T., Zabel, A., Menzel, A.
(See online at https://doi.org/10.1016/j.jmatprotec.2014.02.022) - (2014): On the thermodynamically consistent modeling of distortional hardening: A novel generalized framework, International Journal of Plasticity, Vol. 63, 170-182, 2014
Shi, B., Bartels, A., Mosler, J.
(See online at https://doi.org/10.1016/j.ijplas.2014.05.008) - (2014): Simulation of strain induced anisotropy for polymers with weighting functions. Arch. Appl. Mech., 84(1), S. 21-41
Mahnken, R., Dammann, C.
(See online at https://doi.org/10.1007/s00419-013-0780-3) - (2014): Towards the Multi- Scale Simulation of Martensitic Phase-Transformations: An Efficient Post-Processing Approach Applied to Turning Processes. Journal of Materials Processing Technology, 214 (2014) 8, S. 1516 - 152
Ostwald, R., Tiffe, M., Bartel, T., Zabel, A., Menzel, A., Biermann, D.
(See online at https://doi.org/10.1016/j.jmatprotec.2014.02.022) - (2015): Computer Methods in Applied Mechanics and Engineering: An energy-barrier-based computational micro-sphere model for phase-transformations interacting with plasticity, 2015, Volume 293
Ostwald, R., Bartel, T., Menzel, A.
(See online at https://doi.org/10.1016/j.cma.2015.04.008) - (2015): Fast Solvers for Unsteady Thermal Fluid Structure Interaction International Journal for Numerical Methods in Fluids, Vol. 79, S. 16–29
Birken, P., Gleim, T., Kuhl, D., Meister, A.
(See online at https://doi.org/10.1002/fld.4040) - (2015): Influence of Short Austenitization Treatments on the Mechanical Properties of Low-Alloy Steels for Hot Forming Applications. Metallurgical and Materials Transactions A. – 2015. - Vol. 49 (7). - S. 3199-3207
Holzweissig, M.J., Lackmann, J., Konrad, S., Schaper, M., Niendorf, T.
(See online at https://doi.org/10.1007/s11661-015-2907-3) - (2015): Nonlinear Thermo-Electromagnetic Analysis of Inductive Heating Processes. Archive of Applied Mechanics, Vol. 85, S. 1055-1073
Gleim, T., Schröder, B. & Kuhl, D.
(See online at https://doi.org/10.1007/s00419-014-0968-1) - (2015): Planning and Optimisation of Manufacturing Process Chains for Functionally Graded Components — Part 2: Case Study on Self-Reinforced Thermoplastic Composites Production Engineering — Research and Development, 9 (2015) 3, S. 405-416
Biermann, D., Gausemeier, J., Heim, H.-P., Hess, S., Petersen, M., Ries, A., Wagner, T.
(See online at https://doi.org/10.1007/s11740-015-0610-2) - (2015): Small strain plasticity: classical versus multifield formulation. Archive of Applied Mechanics, Vol. 85, S. 1127-1145
Schröder, B., Kuhl, D.
(See online at https://doi.org/10.1007/s00419-015-0984-9)
