Subproject B4

Integration of Functional Materials

Uncertainty prevails in the development and utilization phase of a load carrying system and leads to an undesired over- or even undersizing of the parts. Misjudged load scenarios or unconsidered influencing factors as well as aging symptoms lead to inadequately designed components.

A possible approach to control this uncertainty is to extend the functionality of the mechanical components by adding sensory and actuatory capabilities to the parts. By this it is possible to reduce ignorance and to enhance the adaptability of the system. The subproject “Integration of Functional Materials” therefore investigates the fundamentals of synchronous joining and forming of structural and functional components. The focus of the first funding period was to prove the feasibility of the process. Functional materials could be integrated without damage.

The second funding period dealt with the acquisition of component stresses for process monitoring. In the ongoing third period, the component signals acquired during the sensor signals are now used in order to achieve a constant product quality despite fluctuating input variables. Control rules are derived for this purpose. In addition, new approaches for controlling model uncertainty are derived, which become possible by the direct measurement of component stresses throughout the life cycle of the part. The axial-oriented sensor forms of the first two funding periods are expanded by torque-sensing sensory components, for which an adaptation of the contact surfaces is required.

Schematic representation of the rotary swaging process
Forming simulation of the joining process. Left: Comparison of the simulated and measured force profiles. Right: Comparison of three sectional views at different times
  Name Contact
Subproject Managers
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. Peter Groche
+49 6151 16-23143
Scientific Staff
Nassr Al-Baradoni M.Sc.
+49 6151 16-23187