Project Details
Projekt
TRR 10: Integration of Forming, Cutting and Joining for the Flexible Manufacture of Lightweight Frame Structures
Subject Area
Mechanical and Industrial Engineering
Materials Science and Engineering
Materials Science and Engineering
Term
from 2003 to 2014
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 5485733
The developments in the automobile industry are, among other things, influenced by legal factors and changing customer needs. On the one hand, legislation demands a decrease of carbon dioxide emissions, on the other hand, increased crash requirements have to be fulfilled. The customer, in turn, expects enhanced safety and improved comfort as to equipment.
There is so far, independent of the material, no economically reasonable process chain for the production of lightweight frame structures in small numbers. The shaping tools of the conventional process chain do not, on the one hand, amortise. On the other hand, the one-time effort to achieve the desired production quality is still to extensive, making a manual production often inevitable and thus causing high costs.
Developing the scientific basics and methods for the creation of integrated process chains in terms of automatised and product-flexible limited-lot production of lightweight structures is the main focus of the Transregional Collaborative Research Centre. This is supposed to lead to a reduction of the production costs by means of a rationalisation and a simultaneous increase of flexibility, continuously integrating simulation and involving the construction process.
Within the Research Centre, an exemplary method of connecting the forming, cutting and joining processes by an idealised process chain for the flexible production of lightweight structures is presented. This process chain is exemplarily implemented by the use of selected processes holding a promising future potential. Extrusion of rounded profiles is in terms of forming a decisive aspect of this process. As to cutting, the flying profile separation immediately following the extrusion process, the manufacture of bores, and the bar end preparation for the joint setup are considered. Joining profiles to an entire structure exemplarily takes place by laser welding as well as by joining by forming using working media and working energies.
In order to integrate the process chain, investigations regarding the chaining of the different sub-processes by quantity- , variant- and configuration-flexible bite-, handling- and processing techniques as well as the provision of a closed simulation chain ranging from the forming to the joining process are required. To point out the problems and to illustrate the results, the BMW C1-spaceframe has been chosen as demonstrator.
There is so far, independent of the material, no economically reasonable process chain for the production of lightweight frame structures in small numbers. The shaping tools of the conventional process chain do not, on the one hand, amortise. On the other hand, the one-time effort to achieve the desired production quality is still to extensive, making a manual production often inevitable and thus causing high costs.
Developing the scientific basics and methods for the creation of integrated process chains in terms of automatised and product-flexible limited-lot production of lightweight structures is the main focus of the Transregional Collaborative Research Centre. This is supposed to lead to a reduction of the production costs by means of a rationalisation and a simultaneous increase of flexibility, continuously integrating simulation and involving the construction process.
Within the Research Centre, an exemplary method of connecting the forming, cutting and joining processes by an idealised process chain for the flexible production of lightweight structures is presented. This process chain is exemplarily implemented by the use of selected processes holding a promising future potential. Extrusion of rounded profiles is in terms of forming a decisive aspect of this process. As to cutting, the flying profile separation immediately following the extrusion process, the manufacture of bores, and the bar end preparation for the joint setup are considered. Joining profiles to an entire structure exemplarily takes place by laser welding as well as by joining by forming using working media and working energies.
In order to integrate the process chain, investigations regarding the chaining of the different sub-processes by quantity- , variant- and configuration-flexible bite-, handling- and processing techniques as well as the provision of a closed simulation chain ranging from the forming to the joining process are required. To point out the problems and to illustrate the results, the BMW C1-spaceframe has been chosen as demonstrator.
DFG Programme
CRC/Transregios
Completed projects
- A01 - Multi-Axis Curved Profile Extrusion (Project Heads Homberg, Werner ; Kleiner, Matthias ; Tekkaya, A. Erman )
- A02 - Composite Extrusion (Project Heads Kleiner, Matthias ; Tekkaya, A. Erman )
- A03 - Material systems for reinforced and functional extruded profiles (Project Heads Löhe, Detlef ; Schulze, Volker ; Weidenmann, Kay A. )
- A04 - Compensation of impacts by insteady process conditions during flying cutting (Project Heads Fleischer, Jürgen ; Munzinger, Christian ; Schulze, Volker )
- A06 - Machining of Lightweight Frame Structures (Project Heads Biermann, Dirk ; Zabel, Andreas )
- A07 - Prozesssicheres Fügen von Aluminium-Tragwerksstrukturen mit einem hybriden, bifokalen Lasersystem (Project Head Zäh, Michael Friedrich )
- A09 - Relation between Structure and Properties of Joints (Project Heads Schulze, Volker ; Weidenmann, Kay A. )
- A10 - Joining by Forming (Project Heads Brosius, Alexander ; Marré, Michael )
- A11 - Joining Centre for Lightweight Frame Structures (Project Head Zäh, Michael Friedrich )
- B01 - Integral design, simulation and optimization of extrusion dies (Project Heads Ben Khalifa, Noomane ; Brosius, Alexander ; Kleiner, Matthias ; Schikorra, Marco ; Tekkaya, A. Erman )
- B02 - Simulation of the five-axis milling process (Project Heads Mehnen, Jörn ; Zabel, Andreas )
- B03 - FEM-Analyse der Bauteilbeeinflussung durch spanende Bearbeitung (Project Heads Biermann, Dirk ; Weinert, Klaus D. )
- B04 - Simulation of the Thermal Joining of Lightweight Fram Structures (Project Head Zäh, Michael Friedrich )
- C01 - Design optimization (Project Head Baier, Horst )
- C03 - Flexible gripping and measurement technology (Project Heads Fleischer, Jürgen ; Lanza, Gisela ; Munzinger, Christian )
- C04 - Integration of handling and assembly (Project Heads Fleischer, Jürgen ; Lanza, Gisela ; Munzinger, Christian )
- C06 - Modelling of discrete reinforced compound materials and profiles under highly dynamic loading (Project Head Baier, Horst )
- C07 - Durchgängige Bauteil-Struktur-Simulation für Fertigungsprozessketten (Project Head Zäh, Michael Friedrich )
- T01 - Verbesserung der Werkstoff- und Bauteileigenschaften von Luftfahrtstringern durch Verbundstrangpressen (Project Heads Löhe, Detlef ; Schikorra, Marco )
- T03 - Erweiterung der Frässimulation zur Bearbeitung von Leichtbaukomponenten unter Berücksichtigung von Werkzeug- und Maschineneigenschaften (Project Heads Biermann, Dirk ; Surmann, Tobias )
- T05 - Modellierung von Fertigungsaufwänden in der Strukturoptimierung auf der Basis qualitativer Informationen (Project Head Baier, Horst )
- T06 - Effiziente Strangpresssimulation für industrielle Anwendungen (Project Heads Brosius, Alexander ; Tekkaya, A. Erman ; Weidenmann, Kay A. )
- T07 - Rührreibschweißen von Aluminiumstrangpressprofilen mit Kunststoff (Project Head Zäh, Michael Friedrich )
- T09 - High quality laser beam welded seams on the visible surface of body structure components (Project Head Zäh, Michael Friedrich )
- Z - Zentrale Aufgaben des SFB/Transregio 10 (Project Heads Kleiner, Matthias ; Tekkaya, A. Erman )
Applicant Institution
Technische Universität Dortmund
Co-Applicant Institution
Karlsruher Institut für Technologie (KIT)
Campus Süd (aufgelöst); Technische Universität München (TUM)
Campus Süd (aufgelöst); Technische Universität München (TUM)
Spokesperson
Professor Dr.-Ing. A. Erman Tekkaya
