Process-Integrated Projection Welding during Deep Drawing

2016 ◽  
Vol 1140 ◽  
pp. 59-66 ◽  
Author(s):  
Masood Jalanesh ◽  
Andre Miller ◽  
Marco Hehmann ◽  
André Spiekermeier ◽  
Sven Hübner ◽  
...  
Keyword(s):  
Deep Drawing ◽  
Active Surface ◽  
Single Step ◽  
Downstream Process ◽  
Process Step ◽  
Projection Welding ◽  
Process Chains ◽  
Innovative Tool ◽  
Edge Based ◽  
Joining Process

Within deep drawing processes, welding represents an innovative approach to optimising the branched process chains which entail uneconomic process steps in production and transport lines. Previous applications of thermal joining processes in presses required a downstream process step for joining standardised functional elements such as nuts. Within the scope of this publication, a weldable tool system is presented which offers the possibility of welding a deep drawing component to an automatically added non-standardised holder in a single-step deep drawing process without additional dwell time in the bottom dead point. In order to realise this innovative tool system, the interdependencies of deep drawing and projection welding are considered to enable a splash-free welding on flat and curved component areas, such as the rounding of a punch edge. Based on experimental research a special concept for the tool kinematics of welding electronics is drawn up which is based on press kinematics. In addition, this article also deals with electric insulation and the forming forces which have an impact on the welding electrodes integrated into the active surface of the forming tool. Thus, the joining process becomes independent from the type of press.

scholarly journals Load path modelling in single-step deep drawing of rotationally symmetric cups

2019 ◽  
Vol 29 ◽  
pp. 520-527
Author(s):  
Matthias Nick ◽  
Robby Mannens ◽  
Daniel Trauth ◽  
Thomas Bergs
Keyword(s):  
Deep Drawing ◽  
Single Step ◽  
Load Path ◽  
Rotationally Symmetric ◽  
Path Modelling

Hydromechanical Deep Drawing of Funerary Vases: A Suitable Alternative to the Traditional Forming Processes

2007 ◽  
Vol 344 ◽  
pp. 485-492 ◽  
Author(s):  
Paolo Bortot ◽  
Elisabetta Ceretti ◽  
Antonio Fiorentino ◽  
Claudio Giardini
Keyword(s):  
Deep Drawing ◽  
Experimental Tests ◽  
Single Step ◽  
Drawing Process ◽  
Production Environment ◽  
Suitable Alternative ◽  
Hydromechanical Deep Drawing ◽  
Casting Technology ◽  
Fe Simulations ◽  
Volume Production

In the present paper a feasibility study of a funerary vase, made of stainless steel, using the Hydromechanical Deep Drawing process, is presented. The component is currently made of bronze and manufactured by die casting technology in a low volume production environment. To investigate the part feasibility, several FE simulations were implemented using the Aquadraw tool of the explicit FE code Pam Stamp 2G 2005®. The FE simulations showed that HDD process can produce the part in one single step without the requirement of finishing operations such as painting or polishing. Furthermore experimental tests were conducted and the first prototypes were successfully produced.

Statistical Analysis of Forming Processes as a First Step in a Process-Chain Analysis: Novel PRO-CHAIN Components

2012 ◽  
Vol 504-506 ◽  
pp. 631-636 ◽  
Author(s):  
Daniela Steffes-Lai ◽  
Tanja Clees
Keyword(s):  
Statistical Analysis ◽  
Statistical Information ◽  
Process Chain ◽  
Parameter Sensitivity Analysis ◽  
Forming Process ◽  
Process Step ◽  
New Approach ◽  
Chain Analysis ◽  
Process Chains ◽  
Metal Blank

This paper presents a new approach for statistical analysis of process chains, including a parameter sensitivity analysis of each process step as a basis for dimension reduction, and an efficient interpolatory metamodel in order to predict new designs. A Monte Carlo alike evaluation of this metamodel results in the requested statistical information, e.g. quantiles of the output functionals. Numerical results are presented for the forming process of a ZStE340 metal blank of a B-pillar. Additionally, a brief overview of results of the process chain forming to crash is given.

scholarly journals Geospatial Queries on Data Collection Using a Common Provenance Model

2021 ◽  
Vol 10 (3) ◽  
pp. 139
Author(s):  
Guillem Closa ◽  
Joan Masó ◽  
Núria Julià ◽  
Xavier Pons
Keyword(s):  
Web Application ◽  
Distributed Environment ◽  
Levels Of Abstraction ◽  
Geospatial Information ◽  
Error Sources ◽  
Process Step ◽  
Process Chains ◽  
Level Information ◽  
High Level ◽  
The Relationship

Lineage information is the part of the metadata that describes “what”, “when”, “who”, “how”, and “where” geospatial data were generated. If it is well-presented and queryable, lineage becomes very useful information for inferring data quality, tracing error sources and increasing trust in geospatial information. In addition, if the lineage of a collection of datasets can be related and presented together, datasets, process chains, and methodologies can be compared. This paper proposes extending process step lineage descriptions into four explicit levels of abstraction (process run, tool, algorithm and functionality). Including functionalities and algorithm descriptions as a part of lineage provides high-level information that is independent from the details of the software used. Therefore, it is possible to transform lineage metadata that is initially documenting specific processing steps into a reusable workflow that describes a set of operations as a processing chain. This paper presents a system that provides lineage information as a service in a distributed environment. The system is complemented by an integrated provenance web application that is capable of visualizing and querying a provenance graph that is composed by the lineage of a collection of datasets. The International Organization for Standardization (ISO) 19115 standards family with World Wide Web Consortium (W3C) provenance initiative (W3C PROV) were combined in order to integrate provenance of a collection of datasets. To represent lineage elements, the ISO 19115-2 lineage class names were chosen, because they express the names of the geospatial objects that are involved more precisely. The relationship naming conventions of W3C PROV are used to represent relationships among these elements. The elements and relationships are presented in a queryable graph.

scholarly journals Introduction to tailored forming

2021 ◽  
Author(s):  
B.-A. Behrens ◽  
J. Uhe
Keyword(s):  
Collaborative Research ◽  
Lightweight Design ◽  
Production Quality ◽  
Research Centre ◽  
Lightweight Construction ◽  
Forming Process ◽  
Process Chains ◽  
Finishing Processes ◽  
Tailored Forming ◽  
Joining Process

AbstractIn recent years, the requirements for technical components have been increasing steadily. This development is intensified by the desire for products with lower weight, smaller size and extended functionality, but at the same time higher resistance against specific loads. Mono-material components manufactured according to established processes reach their limits regarding conflicting requirements. It is, for example, hardly possible to combine excellent mechanical properties with lightweight construction using mono-materials. Thus, a significant increase in production quality, lightweight design, functionality and efficiency can only be reached by combining different materials in one component. The superior aim of the Collaborative Research Centre (CRC) 1153 is to develop novel process chains for the production of hybrid solid components. In contrast to existing process chains in bulk metal forming, in which the joining process takes place during forming or at the end of the process chain, the CRC 1153 uses tailored semi-finished workpieces which are joined before the forming process. This results in a geometric and thermomechanical influence on the joining zone during the forming process which cannot be created by conventional joining techniques. The present work gives an overview of the CRC and the Tailored Forming approach including the applied joining, forming and finishing processes as well as a short summary of the accompanying design and evaluation methods.

scholarly journals Single step polyol synthesis of highly stable Pt/C/SiO2 catalysts for use in PEMFCs: effects of pH, temperature and W/EG ratio

2022 ◽  
Vol 334 ◽  
pp. 04005
Author(s):  
Eva Sousa ◽  
Sofia Delgado ◽  
Tiago Lagarteira ◽  
Adélio Mendes
Keyword(s):  
Pt Nanoparticles ◽  
Active Surface ◽  
Single Step ◽  
Polyol Synthesis ◽  
Active Surface Area ◽  
Stress Tests ◽  
Electrochemically Active ◽  
Effects Of Ph ◽  
The Stability ◽  
Harsh Conditions

Hybrid supports have been proposed as a new alternative to increase the stability of ORR catalysts used in PEMFCs for automotive applications since they are known to be stable under harsh conditions. In this work, Pt nanoparticles were deposited over C/SiO2, via single-step polyol method, to take advantage of the corrosion-resistance properties of silica nanoparticles. In fact, the synthesis parameters, namely, pH, temperature, and glycol concentration had a remarkable impact on the Pt size-distribution, crystallinity, and dispersion over the C/SiO2 supports. A maximum ORR activity and stability was obtained for Pt/C/SiO2 catalysts produced at 1:6 W/EG (v/v). The addition of SiO2 nanoparticles to the carbon structure showed their ability to effectively inhibit support corrosion and Pt nanoparticles detachment and/or growth, with the pH adjustments being critical for obtaining highly stable C/SiO2 supports. Pt/C/SiO2 synthetized under acidic conditions revealed the highest stability when subjected to accelerated stress tests (ASTs), losing only 30 % of the initial electrochemically active surface area (ECSA) of Pt after 4 000 cycles from 0.6 to 1 V (vs RHE), whereas the commercial Pt/C revealed > 50 % of ECSA loss.

scholarly journals A contribution on versatile process chains: joining with adaptive joining elements, formed by friction spinning

2021 ◽  
Author(s):  
Christian Wischer ◽  
Werner Homberg
Keyword(s):  
Current Knowledge ◽  
Research Work ◽  
Sheet Thickness ◽  
Experimental Investigations ◽  
Initial Material ◽  
Ongoing Research ◽  
Mechanical Joining ◽  
Process Chains ◽  
Wide Range ◽  
Joining Process

AbstractNowadays, manufacturing of multi-material structures requires a variety of mechanical joining techniques. Mechanical joining processes and joining elements are used to meet a wide range of requirements, especially on versatile process chains. Most of these are explicitly adapted to only one, specific application. This leads to a less flexibility process chain due to many different variants and high costs. Changes in the boundary conditions like sheet thickness, or layers, lead to a need of re-design over the process and thus to a loss of time. To overcome this drawback, an innovative approach can be the use of individually manufactured and application-adapted joining elements (JE), the so-called Friction Spun Joint Connectors (FSJC). This new approach is based on defined, friction-induced heat input during the manufacturing and joining of the FSJC. This effect increases the formability of the initial material locally and permits them to be explicitly adapted to its application area. To gain a more detailed insight into the new process design, this paper presents a detailed characterization of the new joining technique with adaptive joining elements. The effects and interactions of relevant process variables onto the course and joining result is presented and described. The joining process comprises two stages: the manufacturing of FSJC from uniform initial material and the adaptive joining process itself. The following contribution presents the results of ongoing research work and includes the process concept, process properties and the results of experimental investigations. New promising concepts are presented and further specified. These approaches utilize the current knowledge and expand it systematically to open new fields of application.

scholarly journals Further development of a numerical method for analyzing the load capacity of clinched joints in versatile process chains

2021 ◽  
Author(s):  
Christian Roman Bielak ◽  
Max Böhnke ◽  
Mathias Bobbert ◽  
Gerson Meschut
Keyword(s):  
Numerical Method ◽  
Process Model ◽  
Load Capacity ◽  
Geometrical Properties ◽  
Capacity Model ◽  
Process Chains ◽  
Wide Range ◽  
Metal Sheets ◽  
Further Development ◽  
Joining Process

In many branches of production, components using large number of joints are combined together to make complex structures. The use of mechanical joining techniques offers the possibility to join structures with a wide range of material/geometry configurations. Due to changing in material properties during the production of formed parts, the robustness of the joint must be guaranteed. In this regard, a numerical method has been developed to predict the geometrical properties of the joint as a function of pre-straining of the metal sheets. In this way, the material combination and the joining tools are to be considered. The resulting metamodels were used to estimate the robustness of the joining process. In this study, the method is extended by a numerical load capacity model, which is generated from the joining process model using an automatic algorithm. The simulation model used for predicting the load capacity is validated by experiments. It is shown that the resulting automatic method is able to completely map a process chain and to predict the load capacity of the mechanical joints under consideration of the pre-strain. Furthermore, the correlation between the pre-strain and the load capacity is presented.

scholarly journals Modelling of thermally supported clinching of fibre-reinforced thermoplastics: Approaches on mesoscale considering large deformations and fibre failure

2021 ◽  
Author(s):  
Benjamin Gröger ◽  
Andreas Hornig ◽  
Arne Hoog ◽  
Maik Gude
Keyword(s):  
Numerical Simulation ◽  
Large Deformations ◽  
Dissimilar Materials ◽  
Single Step ◽  
Arbitrary Lagrangian Eulerian ◽  
Fibre Failure ◽  
Feasibility Robustness ◽  
Contact Models ◽  
Reinforced Thermoplastics ◽  
Joining Process

Thermally supported clinching (Hotclinch) is a novel promising process to join dissimilar materials. Here, metal and fibre-reinforced thermoplastics (FRTP) are used within this single step joining process and without the usage of auxiliary parts like screws or rivets. For this purpose, heat is applied to improve the formability of the reinforced thermoplastic. This enables joining of the materials using conventional clinching-tools. Focus of this work is the modelling on mesoscopic scale for the numerical simulation of this process. The FTRP-model takes the material behaviour both of matrix and the fabric reinforced organo-sheet under process temperatures into account. For describing the experimentally observed phenomena such as large deformations, fibre failure and the interactions between matrix and fibres as well as between fibres themselves, the usage of conventional, purely Lagrangian based FEM methods is limited. Therefore, the combination of contact-models with advanced modelling approaches like Arbitrary-Lagrangian-Eulerian (ALE), Coupled-Eulerian-Lagrangian (CEL) and Smooth-ParticleHydrodynamics (SPH) for the numerical simulation of the clinching process are employed. The different approaches are compared with regard to simulation feasibility, robustness and results accuracy. It is shown, that the CEL approach represents the most promising approach to describe the clinching process.

scholarly journals Mechanical Properties of Co-Extruded Aluminium-Steel Compounds

2017 ◽  
Vol 742 ◽  
pp. 512-519 ◽  
Author(s):  
Susanne Elisabeth Thürer ◽  
Johanna Uhe ◽  
Oleksandr Golovko ◽  
Christian Bonk ◽  
Anas Bouguecha ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Tests ◽  
Steel Tube ◽  
Research Centre ◽  
Tool Geometry ◽  
Case Hardening ◽  
Process Step ◽  
Process Chains ◽  
Ultrasonic Assisted ◽  
Case Hardening Steel

Within the scope of the Collaborative Research Centre (CRC) 1153 novel process chains for the production of hybrid solid components by Tailored Forming are developed at the Leibniz Universität Hannover. The combination of e. g. aluminium with steel allows to produce hybrid compounds with wear-resistant functional surfaces and reduced weight. In these process chains, joining takes place as the first step to produce hybrid semi-finished products by friction welding, cladding, ultrasonic assisted laser welding or co-extrusion, which are subsequently subjected to various forming processes such as forging or impact extrusion. The coaxially joined hybrid semi-finished components investigated in this work were produced by means of the lateral angular co-extrusion (LACE) process using the aluminium alloy EN AW-6082 and the case-hardening steel 20MnCr5. These semi-finished products shall be suited to produce hybrid bearing bushings by die forging in a subsequent process step. Initial investigations for the determination of the process parameters and the appropriate tool geometry were made using a steel rod. In future investigations, a steel tube will replace the steel rod in order to produce hybrid semi-finished products, which can be fully integrated into the process chain. The mechanical properties of the profile were determined at different positions along its length. For this purpose, the quality of the joining zone between aluminium and steel as a function of the profile position was examined by means of push-out tests. Moreover, the mechanical properties of the aluminium component’s longitudinal weld seam were determined by micro-tensile-tests.

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