Publications

The service life of rolling contacts is dependent on many factors. The choice of materials in particular has a major influence on when, for example, a ball bearing mayfail.Within an exemplary process chain for the production of hybrid high-performance components through tailored forming, hybrid solid components made of at least two different steel alloys are investigated. The aim is to create parts that have improved properties compared to monolithic parts of the same geometry. In orderto achievethis, several materials are joined prior to a forming operation. In this work, hybrid shafts created by either plasma(PTA)orlaser metal deposition (LMD-W) welding are formed via cross-wedge rolling(CWR)to investigate the resulting thickness of the material deposited in the area of the bearing seat. Additionally,finite element analysis (FEA)simulations of the CWRprocessare compared with experimental CWR results to validate the coating thickness estimation done via simulation. This allows for more accurate predictionsofthe cladding materialgeometry after CWR,and the desired welding seam geometrycan be selected by calculating the cladding thicknessvia CWR simulation.

Cross-Wedge Rolling, Forming, hybrid, tailored forming

In a research project at the Institute for Integrated Production in Hanover, the process parameters for cross-wedge rolling are to be determined with which an ultrafine microstructure can be achieved in cylindrical blanks. The aim is to achieve grain sizes of the rolled part in the range of 500 nm.

Process development, cross wedge rolling, material properties,Ultra fine microstructure

This paper presents concepts for shock and vibration reduction of a forging tongs. In the forging industry, hand-operated forging tongs are often used for the machining of forged parts. Here, the employees are exposed to high loads from shocks and vibrations of the forming machines. A simulation model that has been created evaluates concepts for reducing the shocks and vibrations during forging

Ergonomics, forging, shock and vibration reduction

Within the project "CoMoGear - Condition Monitoring of Marine Gearboxes based on Wireless, Energy-Autonomous Sensor Nodes", an energy-autonomous, wireless sensor network was developed for condition diagnosis of highly stressed rotating components in marine gearboxes was developed. This allows intelligent, condition-based monitoring and maintenance, paving the way for unmanned shipping.

sensor nodes, condition monitoring, marine gearbox, energy harvesting

Due to their design, the lift mast and attachments on industrial trucks, among other things, can restrict the operator's field of vision. In the project "Virtual visibility improvement and intuitive interaction through augmented reality on industrial trucks (Visier)", this situation is to be counteracted with the development of a new driver assistance system. With the aid of augmented reality (AR) goggles, the aim is to create the conditions for the driver to be able to block out visual restrictions and thus take a look behind the cargo and the mast in order to detect hazards and obstacles at an early stage.

Augmented Reality, assistance system, industrial trucks

In many companies, the demands placed on in-house processes is increasing in order to get the maximum benefit from available capacities. This includes, among other things, avoiding waste of internal capacity. With the optimization of route sheets by adapting the level of detail to the needs of production, a significant contribution can already be made during work preparation. Improving in the provision of information can have a positive impact on the efficiency of a company by reducing non-value-adding activities.

route sheets, work preparation, level of detail, provision of information, MES-implementation

A major challenge of logistics within manufacturing companies is the optimization of transport systems. Due to Industry 4.0, companies are more willing than ever to find and implement as yet unknown rationalization potential in this area. Currently, the use of drones in internal logistics is considered to have such potential. Especially when dealing with unplanned material transports for missing parts in assemblies or spare parts for repairs, the unmanned aerial vehicles could prove to be problem solvers. However, the use of drones is still a largely unexplored area, especially on factory floors.

drones, intralogistics, transport

To manufacture semi-finished hybrid workpieces with tailored properties, a finite element simulation assisted process chain design was investigated. This includes the process steps of cross wedge rolling, hot geometry inspection, induction hardening, and fatigue testing. The process chain allows the utilisation of material combinations such as high-strength steels with low-cost and easy to process steels. Here, plasma transferred arc welding is applied to supply the process chain with hybrid specimen featuring different steel grades. An overview of the numerical approaches to consider the various physical phenomena in each of the process steps is presented. The properties of the component behaviour were investigated via the finite element method (FEM) and theoretical approaches.

Cross-Wedge Rolling, Forming, hybrid, tailored forming

In this work we present an application of the virtual element method (VEM) to a forming process of hybrid metallic structures by cross-wedge rolling. The modeling of that process is embedded in a thermomechanical framework undergoing large deformations. Since forming processes include mostly huge displacements within a plastic regime, the difficulty of an accurate numerical treatment arises. VEM illustrates a stable, robust and quadratic convergence rate under extreme loading conditions in many fields of numerical mechanics. Numerically, the forming process is achieved by assigning time-dependent boundary conditions instead of modeling the contact mechanics yielding to a simplified formulation. Based on the two metallic combinations of steel and aluminum, different material properties are considered in the simulations. The purpose of this contribution is to illustrate the effectiveness of such a non-contact macroscopic framework by employing suitable boundary conditions within a virtual element scheme. A comparison with the classical finite element method (FEM) is performed to demonstrate the efficiency of the chosen approach. The numerical examples proposed in this work stem out from the DFG Collaborative Research Centre (CRC) 1153 “Process chain for the production of hybrid high-performance components through tailored forming”.

simulation, FEM, bulk metal forming, tailiored forming

Hybrid compound forging of aluminum bulk parts and steel sheet metals is a combination of material lightweight design and structural lightweight design. During this process, an aluminum bulk part and a steel sheet metal are combined and formed simultaneously. A material joint is generated by deforming, using zinc as solder material. This prevents the generation of brittle intermetallic Fe-Al-Phases as well as contact corrosion. The zinc layer is applied to the aluminum bulk part by hot dipping. To create a material locking connection by forming, suitable parameters such as the forming temperature are identified in first experimental trials. Microsections showed that the zinc layer is still intact after forming. In this paper the investigation of the effects of different steps of forming and different geometries of the aluminum bulk part surface on the joint strength are described. The forming tests show that a further forming of the aluminum part, resulting in a bigger deformation, leads to a stronger connection between both joining partners. But there is a limit to the forming since the applied forces can transfer to the steel sheet leading to an unintended deformation. The generated hybrid parts are tested for their ability for further forming. Therefore, the joined hybrid parts are undertaken a deep drawing process to see if the joint withstands further forming of the hybrid part.

aluminium, hybrid forging, lightweight construction, hybrid

If companies select a suitable transport system already during the factory planning stage, they can avoid subsequent adjustments and save a lot of time and costs. The IPH is developing a software demonstrator for automated layout and transport system planning.

factory planning, fuzzy logic, transport selection, routing

Development of a methodologically procedure to enable companies to trade their free or required capacities by using a digital platform. The cross-sectoral digitalization of the economy not only leads to the creation of innovative products and services, but also to a change in existing market logics. Digital platforms are increasingly being regarded as growth and innovation drivers of digital change [2]. By linking the sharing economy in form of capacity sharing with digital platforms, companies can sell or purchase their free or required capacities across companies and thus counteract negative consequences of under- or overloading (such as short-time work or overtime).

capacity sharing

Handling hot steel parts weighing several kilos is physically demanding. A new type of forging tongs is designed to reduce stress at work, prevent pain and reduce sick leave.                             

forging, ergonomic, stress reduction

The selection of storage, commissioning and transport systems (sct systems) is very complex due to the large number of available systems on the market and influencing factors. One important influencing factor is automation. To classify the degrees of automation of sct systems and to determine the individually required automation a method is proposed below.

automation, storage, commissioning and transport systems

Upfront investment costs for the tooling of injection molds are the basis for deciding if a mold is tooled and hence if a part is viable for mass-production. If tooling costs are too high, a product may not viable for production. If tooling costs are estimated too low by the tool shop, contract implications may arise.
The goal of this research is to develop a method with humanlike quotation accuracy, achieve standardization, factor in historic quotation data and shorten quotation process times. The machine learning approach developed is based on geometry data of parts and additional meta-information.

injection molding, tooling, industry 4.0

The aim of subproject B1 of the Collaborative Research Center (CRC) 1153 is to determine the formability of novel hybrid semi-finished products by means of incremental forming cross wedge rolling. Main aspect is the forming of hybrid semi-finished products made of steel, aluminium and hard material alloys. In order to reduce the component weight, the use of hybrid semi-finished products makes it possible to manufacture less stressed segments of a previously monolithic component from a light metal. To increase wear resistance, a component area (e.g. a bearing seat) can be coated with a hard material. In addition, process variables (e.g. temperature and force) are to be measured in contact between work piece and tool in the future. There are primarily two material arrangements for the semi-finished products used: coated (coaxial - demonstrator shaft 1) and joined at the front (serial - demonstrator shaft 3). One challenge is the heating of the semi-finished products necessary for forming, since the hybrid semi-finished product has different flow resistances due to the different materials and may have to be heated inhomogeneously in order to enable uniform forming.

cross-wedge rolling, forming, hybrid work pieces, tailored forming, hybrid semi-finished products

The Collaborative Research Centre 1153 (CRC 1153) “Process chain for the production of hybrid high-performance components through tailored forming“ at the Institute for Integrated Production in Hanover/Germany is opening up further potential for hybrid solid components. On the basis of a new type of production process, tailored semi-finished products already joined prior to forming are to be used.

tailored forming, cross-wedge rolling, forming, aluminium, steel

Quality assurance methods are a central success factor for the further industrialization of additive manufacturing. This paper presents an approach for an optical inspection system that controls the quality of additive material extrusion layer by layer. The inspection task gets analyzed, hardware components for data acquisition are designed and a first step towards texture-analytical detection of defects is presented.

additive manufacturing, 3d printing, material extrusion, fused deposition modeling, image processing

How ergonomic is my workplace? Scientists from Hanover have developed evaluation software that can answer this question quickly and objectively. The digital ergonomics evaluator is particularly helpful for small and medium-sized companies: In the future, they will be able to carry out ergonomics assessments without much effort to protect their assembly workers from back and knee pain, tendonitis or similar problems.

ergonomical assessment, industry 4.0, 3D camera

Thanks to digital assistants, even low-skilled workers can perform complex tasks - the example of SCHUBS GmbH shows this. The company manufactures customized control cabinets and is an important employer for people with disabilities. Schubs would like to introduce a digital assistance system so that they can take on more responsible tasks in the future. The Mittelstand 4.0 Competence Center Hanover developed the demonstrator for this.

assistance systems, digitization

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