TRR 10: Integration of Forming, Cutting and Joining for the Flexible Manufacture of Lightweight Frame Structures
Materials Science and Engineering
Final Report Abstract
An important result of the Transregio is the integrated process chain and the development of technologies for an automated and product-flexible small-series production of lightweight frame structures. Here, especially the flexibility in terms of applicability in different quantities, the applicability at a high diversity of variants, and the manufacturability have to be highlighted. Products for lightweight frame structures vary in shape, size and in their application and often possess customized properties. For small quantities and a high diversity of variants, processes with a tool-based form of production are usually uneconomical. For this reason processes with a kinematic shape generation should be enhanced and qualified so that they are suitable for the increased manufacturing complexity. In order to reduce the number of processes and component-related interfaces between the single manufacturing steps, the vertical range of manufacture has to be decreased by an increased technological integration. To achieve this, the large number of simple processes is replaced by less, but more complex manufacturing methods. For this purpose, the profile extrusion process was extended in the Transregio. Innovative manufacturing methods such as the curved profile extrusion, the extrusion of profiles with variable wall thicknesses, and the composite extrusion were developed. The composite extrusion process allows the use of metallic wires or hybrid ceramic fiber composite wires as reinforcing elements and glass fibers or insulated electrical conductors as functional elements. To predict the quality of the embedding by on quasi-stationary process simulations and to allows an automatic optimization, methods have been developed on the basis of algorithms such as the "Evolutionary Algorithms" from computer science. To provide an insight into the failure behavior of the new components, new methods for the material characterization such as micro-push-out tests, in-situ testing methods using acoustic emission analysis, and in-situ tensile tests with a computer tomography imaging were developed. The handling of the profiles was performed with a flexible and intelligent gripping technology, which can also be used for the measurement and arrangement of the profiles by means of a geometrydependent component system scale. The high qualitaty processing of these profiles was partly achieved through the use of real-time acoustic emission systems, which can identify material intersections. Due to that e.g. machining processes can be interrupted just before reaching the reinforcing elements inside a composite profile. For the prediction, process planning, and optimization of milling processes for the production of lightweight, reinforced structural and node components made of aluminum, a simulation framework was developed, which allows to predict the essential process variables including their influences. Due to the combination of YAG and high power diode lasers for bifocal-hybrid-laser-welding, a doubling of the welding speed compared to conventional methods could be achieved. Furthermore, a 25 % higher strength was obtained in a benchmark on flat samples at quasi-static as well as at dynamic loads in comparison to the WIG process. For the bifocal-hybrid-laser-beam-welding and for the friction stir welding a flexible heat source model was developed that can predict the process-specific distortion and the residual stresses of the considered component geometries by means of numerical calculations. In addition, for force-fit joining methods of profile-profile connections, the internal-high-pressure-joining and for sheetprofile connections the magnetic pulse welding were analyzed. Methods for integrated consideration of structural mechanics and production engineering aspects were developed for the design optimization of extruded (composite) components and structures. Due to these methods, construction designs for any semi-finished products and components can be derived. The developed methods of the design optimization were used for dynamic impact processes (crash) and were extended to verify the robustness of deviations from the nominal of the determined design. On the material and the structural mechanics level, a model and the simulation of reinforced composites profiles were set up, that can be used to predict the elastic and strength behavior of heterogeneous reinforced composite profiles in an early design stage. By the use of cruciform specimens, whose geometry was optimized for the reinforced material, the failure criterion and the consideration of the homogenized material for strength analysis could be verified. Fracture mechanics and high dynamic impact loads were considered as well.
Publications
- FEM-Analyse der Bauteilbeeinflussung dünnwandiger Profile durch spanende Bearbeitung. Aluminium, International Journal for Industrie, Research and Application, Volume 80 12/December 2004, S. 1408-1413
K. Weinert, C. Peters, M. Kersting
- Finite Element Modelling Concepts of the Load Application on Thin Walled Profiles During the Drilling Process. Production Engineering – Research and Development, Annals of the German Academic Society for Production Engineering, XI (2004) 2, S. 121- 124
K. Weinert, N. Hammer, C. Peters, M. Schulte
- Fliegendes Abtrennen Aluminium, International Journal for Industrie, Research and Application, Volume 80 12/December 2004, S. 1378-1382
J. Fleischer, S. Kies, G. Stengel
- Vergleich des hybriden, bifokalen Laserschutzgasschweißens mit Laser-MIG-Hybridverfahren. Aluminium, International Journal for Industry, Research and Application, Volume 80 12/December 2004, S. 1387-1392
M.F. Zäh, A. Trautmann
- Innovative Machine Kinematics for Combined Handling and Machining of Three-Dimensional Curved Lightweight Extrusion Structures. Annals of the CIRP, 54 (2005), S. 317-320
J. Fleischer, J. P. Schmidt-Ewig
(See online at https://doi.org/10.1016/S0007-8506(07)60112-7) - 3D-Laser Processing of Spatially Curved Profiles. Advanced Materials Research: Flexible Manufacture of Lightweight Frame Structures, Band 10 (2006) S. 43-52
J. Fleischer, S. Kies, C. Munziger, R.Rilli
(See online at https://doi.org/10.4028/www.scientific.net/AMR.10.43) - Design Optimization for hybrid material structures. Int. Journal for Structural and Multidisciplinary Optimization, Springer Verlag, 2006
H. Baier, M. Huber, H. Langer
(See online at https://doi.org/10.1007/s00158-007-0204-5) - Laser Bifocal Hybrid Welding of Aluminum. Advanced Materials Research: Flexible Manufacture of Lightweight Frame Structures, Band 10 (2006) S. 65-79
M.F. Zäh, A. Trautmann
(See online at https://doi.org/10.4028/www.scientific.net/AMR.10.65) - A Modelling Approach for the Manufacturing Process Chain of Composite Lightweight Structures. Advanced Materials Research, Vol. 43 (2008), S. 157-166
M. Langhorst, M. F. Zaeh
(See online at https://doi.org/10.4028/www.scientific.net/AMR.43.157) - Bifocal Hybrid Laser Beam Welding and Friction Stir Welding of Aluminium Extrusion Components. Advanced Material Research, Vol 43., S. 69-80, 2008
M. F. Zäh, S. Huber, P. Gebhard, M. Ruhstorfer
(See online at https://doi.org/10.4028/www.scientific.net/AMR.43.69) - Dynamics and Temperature Simulation in Multi-Axis Milling In: Advanced Materials Research: Flexible Manufacture of Lightweight Frame Structures - Phase II: Integration , Volumes 43 (2008), S. 89-69, ISBN 0-87849-385-9
E. Ungemach, T. Surmann, A. Zabel
(See online at https://doi.org/10.4028/www.scientific.net/AMR.43.89) - Experimental investigation of embedding high strength reinforcements in extrusion profiles. In: CIRP Annals - Manufacturing Technology, Volume 57, Issue 1, 2008, Pages 313-316
M. Schikorra, A. E. Tekkaya, M. Kleiner
(See online at https://doi.org/10.1016/j.cirp.2008.03.024) - Flexible manufacturing of Lightweight Frame Structures - Phase II: Intergartion. Advanced Materials Research, Volumes 43 (2008), ISBN 0-87849-385-9
K. Weinert, J. Fleischer, A. E. Tekkaya, M. Zäh, M. Schikorra
- Knowledge-Based Modeling of Manufacturing Aspects in Structural Optimization Problems. In: Advanced Materials Research: Flexible Manufacture of Lightweight Frame Structures - Phase II: Integration , Volumes 43 (2008), S.111-122
M. Huber, Ö. Petersson, H. Baier
(See online at https://doi.org/10.4028/www.scientific.net/AMR.43.111) - Mechanical Modelling of Wire Reinforced Metal Matrix Extrusion Profiles. Advanced Materials Research Volume 43 (2008), S. 145-156
M. Wedekind, H. Baier
(See online at https://doi.org/10.4028/www.scientific.net/AMR.43.145) - Metal forming progress since 2000. CIRP Journal of Manufacturing Science and Technology, 1, (2008), S. 2-17
J. Jeswiet, M. Geiger, U. Engel, M. Kleiner, M. Schikorra, J. Duflou, R. Neugebauer, P. Bariani, S. Bruschi
(See online at https://doi.org/10.1016/j.cirpj.2008.06.005) - New Aspects of Joining by Compression and Expansion of Tubular Workpieces (Keynote Paper) International Journal of Material Forming, Springer Paris, ISSN 1960-6206 (Print) 1960-6214 (Online)
M. Marré; A. Brosius; A. E. Tekkaya
(See online at https://doi.org/10.1007/s12289-008-0140-y) - Prototype Manufacturing of Extruded Aluminum Aircraft Stringer Profiles with Continuous Reinforcement. Advanced Materials Research: Flexible Manufacture of Lightweight Frame Structures - Phase II: Integration , Volumes 43 (2008), S.167-174
T. Kloppenborg, T. Hammers, M. Schikorra, E. Kerscher, A. E. Tekkaya, D. Löhe
(See online at https://doi.org/10.4028/www.scientific.net/AMR.43.167) - Innovation by Forming Technology: Motivation for Research International Journal of Material Forming, Springer Verlag, ISSN 1960-6206, Volume 2, S. 29-38
M. Wedekind, H. Baier
(See online at https://doi.org/10.1007/s12289-009-0656-9) - Manufacturing of Leightweight Frame Structures by innovative Joining by Forming Processes. International Journal of Material Forming, 2009
M. Marré, M. Ruhstorfer, A. E. Tekkaya, M. F. Zäh
(See online at https://doi.org/10.1007/s12289-009-0524-7) - Position and contour detection of spatially curved profiles on the basis of a component-specific scale. CIRP Annals - Manufacturing Technology, Jahrgang 2009, Heft/Band Volume 58, Issue 1, S. 481-484
J. Fleischer, C. Munzinger, G. Lanza, D. Ruch
(See online at https://doi.org/10.1016/j.cirp.2009.03.040) - Numerical Material Flow Optimization of a Multi-Hole Extrusion Process. Advanced Materials Research; Band 83-86, 2010, S. 826-833, Trans Tech Publications, Schweiz
T. Kloppenborg, S. Schikorra, A. E. Tekkaya
(See online at https://doi.org/10.4028/www.scientific.net/AMR.83-86.826) - Towards the flexible and near-net-shape production of three-dimensionally curved extrusion profiles. Production Engineering, 2010, Springer Verlag, Berlin / Heidelberg, ISBN/ISSN 1863-7353
M. Schneider, G. Koehler, D. Becker, A. Selvaggio, A. E. Tekkaya, C. Munzinger, V. Schulze, M. Kleiner
(See online at https://doi.org/10.1007/s11740-010-0246-1) - Advanced manufacturing and design techniques for lightweight structures. International Aluminium Journal (2011), Vol. 9, Seiten 60 - 64
J. Both, T. Brueggemann, S. Dosch, J. Elser, M. Kronthaler, A. Morasch, M. Otter, D. Pietzka, A. Selvaggio, C. Weddeling, E. Wehrle, F. X. Wirth, H. Baier, D. Biermann, A. Brosius, J. Fleischer, G. Lanza, V. Schulze, A. Tekkaya, A. Zabel, M. F. Z.
- Influence of groove characteristics on the strength of form-fit joints. Journal of Materials Processing Technology (2011), Vol. 211, Issue 5, ISSN 0924-0136
C. Weddeling, S. Woodward, M. Marré, J. Nellesen, V. Psyk, A. E. Tekkaya, W. Tillmann
(See online at https://doi.org/10.1016/j.jmatprotec.2010.08.004) - Simulation of the Temperature Distribution in NC-Milled Workpieces. Proceedings of the 13th CIRP Conference on Modelling of Machining Operations, 2011, Sintra, Portugal, J.C. Outeiro (Hrsg.), ISBN 978-3-03785-095-4, S. 222-230
T. Surmann, E. Ungemach, A. Zabel, R. Joliet, A. Schröder
- Compensation of shape deviations for the automated assembly of space frame structures. 4th CIRP Conference on Assembly Technologies and Systems, 20.-22.05.2012, Ann Arbor, Michigan, USA, Band , Technologies and Systems for Assembly Quality, Productivity and Customization, ISBN: 978- 0-615-64022-8, S. 105-108
J. Fleischer, M. Otter
- Lightweight Construction by Means of Profiles Key Engineering Materials, Volumes 504 - 506, S. 369-374
S. Chatti, D. Pietzka, N. Ben Khalifa, A. Jäger, A. Selvaggio, A. E. Tekkaya
(See online at https://doi.org/10.4028/www.scientific.net/KEM.504-506.369) - Modelling and Visualization of the Surface Resulting from the Milling Process. Computer Graphics Edited by Nobuhiko Mukai, ISBN 978-953-51-0455-1, Publisher: InTech, 2012
T. Surmann
(See online at https://doi.org/10.5772/35792) - Numerical Investigation of the Influence of Preliminary Manufacturing Processes on the Crash Behaviour of Automotive Body Assemblies. International Journal of Advanced Manufacturing Technology, 2012
L. Papadakis, A. Schober, M. F. Zäh
(See online at https://doi.org/10.1007/s00170-012-4224-y) - Spatial alignment of joining partners without fixtures, based on component-inherent markings. 4th CIRP Conference on Assembly Technologies and Systems, 20.-22.05.2012, Ann Arbor, Michigan, USA, Band , Technologies and Systems for Assembly Quality, Productivity and Customization, ISBN 978- 0-615-64022-8, S. 17-20
J. Fleischer, J. Elser
- Lifetime behaviour of unidirectionally wire reinforced lightweight metal matrix composites. International Journal of Fatigue 56 (2013), S. 60 - 68
M. Merzkirch, V. Schulze, K. A. Weidenmann
(See online at https://doi.org/10.1016/j.ijfatigue.2013.08.002) - Modeling approach for the determination of material flow and welding conditions in porthole die extrusion with gas pocket formation. Key Engineering Materials Vols. 554-557 (2013), S. 787-793
M. Schwane, F. Gagliardi, A. Jäger, N. Ben Khalifa, A. E. Tekkaya
(See online at https://doi.org/10.4028/www.scientific.net/KEM.554-557.787) - Spatial alignment of joining partners without fixtures, based on component inherent markings. Journal of Manufacturing Systems, Elsevier, 2013
J. Fleischer, G. Lanza, M. Otter, J. Elser
(See online at https://doi.org/10.1016/j.jmsy.2013.04.004) - Cyclic deformation and damage behaviour of the spring steel wire reinforced aluminum alloy EN AW-6082. Journal of Materials Science 49, 2187-2203
M. Merzkirch, A. Reeb, V. Schulze, K. A. Weidenmann
(See online at https://doi.org/10.1007/s10853-013-7913-5) - Development of an automatic modal pendulum for the measurement of frequency responses for the calculation of stability charts. Proceedings of the 9th CIRP Conference on Intelligent Computation in Manufacturing Engineering, Capri (Naples), 2014
T. Brüggemann, D. Biermann, A. Zabel
(See online at https://doi.org/10.1016/j.procir.2015.06.090) - Extrusion of Profiles with Variable Wall Thickness. Procedia CIRP, Volume 18, 2014, Pages 15-20
A. Selvaggio, M. Haase, N. Ben Khalifa, A.E. Tekkaya
(See online at https://doi.org/10.1016/j.procir.2014.06.100) - Material modelling for crash simulation of thin extruded aluminium sections. International Journal of Crashworthiness
A. Morasch, D. Matias and H. Baier
(See online at https://doi.org/10.1080/13588265.2014.916835) - Simulation of composite hot extrusion with high reinforcing volumes. Procedia Engineering 81 ( 2014 ) 1265-1270
M. Schwane, T. Citrea, C. Dahnke, M. Haase, N. Ben Khalifa, A. E. Tekkaya
(See online at https://doi.org/10.1016/j.proeng.2014.10.108) - Analytical Methodology for the Process Design of Electromagnetic Crimping Journal of Materials Processing Technology, 2015
C. Weddeling, O. K. Demir, P. Haupt, A. E. Tekkaya
(See online at https://doi.org/10.1016/j.jmatprotec.2015.02.042)
