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SFB 666:  Integral Sheet Metal Design with Higher Order Bifurcations - Development, Production, Evaluation

Subject Area Mechanical and Industrial Engineering
Materials Science and Engineering
Mathematics
Term from 2005 to 2017
Project identifier Deutsche Forschungsgemeinschaft (DFG) - Project number 13000367
 
Final Report Year 2017

Final Report Abstract

Finding technical solutions for current, challenging problems is one of the most important driving factors for creating innovations. The design tasks are particularly demanding, if not only sufficient but also the best possible solutions are to be worked out taking into account all relevant boundary conditions and requirements. Product development methods that have been applied so far neglect a particularly important driver for product developments to a large extent: manufacturing technologies. On the basis of numerous case studies, the CRC 666 has shown that manufacturing knowledge is extremely important for product development in order to find the best technical solutions. However, this knowledge is generally not available to the product designers in a usable form. Therefore, many possibilities for utilizing manufacturing-induced properties are not exhausted. Starting from the novel methods of linear flow splitting and combinations with known manufacturing technologies, fascinating design possibilities for sheet metal products could be systematically developed within the work of the CRC 666. Thus, the overall goal of the CRC 666 was fully achieved: the creation of a consistently formalized approach to exploit the technological potential of new processes for an optimized product design. Within the funding periods of the SFB 666, a new approach for an integrated algorithm-based product and process development was gradually developed which now allows a comprehensive view of product and process information using mathematical algorithms for the first time. For the aimed integral production of thin-walled, branched structures made of high-strength and ultra-highstrength sheet metal without a material doubling in a continuous flow production at room temperature, extensive process and method developments as well as validations were carried out in the CRC 666. Successfully, the process potentials of the rolling processes of linear flow splitting and linear bend splitting have been developed and combined with cutting and bending processes to completely new design possibilities for profile components. This also includes durable and reversible profile connections in which the high-strengthened branched areas were specifically positioned in the connection zones. Starting from the mechanisms of linear flow splitting, important knowledge into severe plastic deformation (SPD) methods have been developed in material-scientific research. In particular, the coupling with investigations on the operational and rolling strength, allowed to quantify the advantageous property changes by the highly plastic deformation. The flexible linear flow splitting developed within the CRC 666 represents a manufacturing technology which is outstanding in terms of its product and process flexibility. Within the individual funding periods the work of the CRC 666 was followed by a research roadmap that has been designed with increasing demands on geometric complexity, optimized functionalities and modeling depth. Numerous scientists working in the CRC 666 have been able to further improve their scientific qualifications by means of challenging and interdisciplinary tasks. Today, they occupy challenging positions in business and science. All scientific findings of the CRC were documented in a joint book publication.

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