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TRR 402:  Intelligent production technologies for lightweight plastic structures with load-dedicated 3D grading of the reinforcement architecture

Subject Area Mechanical and Industrial Engineering
Term since 2025
Project identifier Deutsche Forschungsgemeinschaft (DFG) - Project number 525069572
 
Future technology and product developments will be measured by the increase in resource efficiency for sustainable climate protection with a significant reduction in greenhouse gas emissions. In order to implement the necessary measures in mobile applications, lightweight construction technologies for the largescale production of low-mass components have a particularly broad impact. Accordingly, the main objective of the planned SFB/TRR is to research mechanisms of action for the fusion of plastic-based technologies for the production of lightweight structures that exhibit load-dedicated 3D grading of the reinforcing structure. The research work focuses on combination technologies of compossible in-line and in-situ pro-duction processes that are characterised by their suitability for large-scale production, in particular injection moulding and pressing. The main focus is on transitions between continuous and discontinuous fibre reinforcement. Based on a coupled simulation and multi-criteria optimisation, the hybridisation of such processes and structures requires a targeted adaptation of material, geometry and process parameters. As part of the CRC/TRR, the so-called elementary profile structure component (EPS) and the elementary flat structure component (EFS), which are being investigated in the basic injection moulding and pressing production groups, serve to provide technological proof of the calculated and optimised grading in the FRP/plastic transition area. The focus is on the analysis and control of the processes for the gentle integration of the locally and globally graded semi-finished products and for the process-inherent modification of the fibre architecture. The data required to quantify the environmental impact of fibrereinforced plastic constructions must be supported by the introduction of product life cycle management from the design phase onwards. This is made possible by storing all the necessary data and parameters along the entire value chain, from the requirements to the geometry, material properties and process conditions through to the structural behaviour. It is crucial that the necessary parameters are identified from a life cycle assessment perspective and harmonised with the sub-projects in order to support a holistic approach. Advanced methods based on new approximation strategies are being developed for research into intelligent compostable production technologies. Comprehensive processing of data and models from the design, analysis, production and recycling processes is necessary to allow appropriate feedback into a centralised intelligent development and pro-duction system (iDP system). Based on a catalogue of requirements for a lightweight structure and predefined optimisation criteria, the iDP system generates the best possible solutions.
DFG Programme CRC/Transregios
International Connection Austria

Current projects

Applicant Institution Technische Universität Chemnitz
Participating University Technische Universität Wien
 
 

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