TRR 30:  Process-integrated Manufacturing of Functionally Graded Structures Based on Coupled Thermo- mechanical Phenomena

• Subject Area: Mechanical and Industrial Engineering ; Materials Science and Engineering
• Term: from 2006 to 2015
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 14802874

The preservation of modern industrial fabrication lines for the mass production of top quality components - even under the high-wage conditions of western industrial nations - is only attainable by extraordinary innovations. The resulting phenomena of complex interactions of thermal and mechanical mechanisms offer a prospective potential in the context of industrial plastic and metal processing techniques concerning the freedom of process design, which up to now is not yet exploited. The designated research objective of the present Transregional Collaborative Research Centre is the creation of those micro- and macroscopic product structures, that are not possible by conventional processing routines or only under inefficient conditions.
The degree of innovation consists of not only the flexibilisation of geometrical product properties under efficient process conditions but especially the extensive flexibilisation of the resulting microstructural properties due to controlled influences of the forming process. Especially design criteria, allowing a functional gradation of properties adapted to the product application profile, are in the centre of interest. Therefore a new techology for the fabrication of functional graded components is aimed to be established by this approach in the frame of this Transregional Collaborative Research Centre.
New approaches only based on experimental investigations of the correlations between thermo-mechanical process conditions and characteristic product properties are not sufficient for a sustainable foundation of such innovative product and process designs. In fact the complexity of the interacting mechanisms demands the development of advanced modelling techniques including adequate mathematical and numerical algorithms. Not until then a realistic and reliable prediction of the course of such processes become possible in order to arrange the required set of static and dynamic process parameters if necessary implemented into appropriate computer-aided tools which lead to the reproducible desired product property profile.

• DFG Programme: CRC/Transregios

Completed projects

• A01 - Investigation of plastic forming under the influence of locally and temporally variable temperature and stress states (Project Head Weidig, Ursula )
• A02 - Thermo-mechanical processing of high-strength aluminium materials during the extrusion process (Project Head Tekkaya, A. Erman )
• A03 - Experimental and simulative analysis of the machining of inhomogeneous workpieces (Project Heads Biermann, Dirk ;  Zabel, Andreas )
• A04 - In-process-fabrication and application of horizontally and vertically graded microstructures of tool coatings under application of deposition methods (TS+PVD) (Project Head Tillmann, Wolfgang )
• A05 - Thermo-mechanical match mould forming of self-reinforced thermoplastic gradient materials (Project Head Heim, Hans-Peter )
• A07 - Thermal assisted incremental forming of tubes and sheets with process-integrated heat generation (Project Head Homberg, Werner )
• A08 - Graded structures in amorphous polymers: fabrication of self-reinforced polycarbonate (Project Head Schöppner, Volker )
• B01 - Thermo-rheological material modeling of polymers using non-linear material laws (Project Heads Mahnken, Rolf ;  Wünsch, Olaf )
• B02 - Simulation of a hybrid-forming process considering thermal shock behaviour in the forming tool and phase transformations in the workpiece (Project Head Mahnken, Rolf )
• B03 - Dynamic microstructural changes in thermo-mechanically coupled processes (Project Head Schaper, Mirko )
• B04 - Modelling and simulation of material and component behaviour of aluminium alloys in coupled thermo-mechanical manufacturing processes (Project Heads Mosler, Jörn ;  Svendsen, Robert )
• B05 - Modellierung und Simulation von gekoppelten thermoplastischen und thermoviskosen Strukturgestaltungs- und Formgebungsprozessen (Project Head Matzenmiller, Anton )
• B06 - Modelling and simulation of thermo-mechanically induced phase transformations in steel (Project Heads Bartel, Thorsten ;  Menzel, Andreas )
• C01 - Time-Adaptive Computation of Finite Thermoviscoplastic Structures (Project Head Kuhl, Detlef )
• C02 - Asymptotic based simulation of thermo-mechanical cooling processes (Project Head Meister, Andreas )
• C03 - Efficient numerical techniques for non-isothermal, highly viscous multiphase flow for the processing of graded plastics (Project Head Turek, Stefan )
• D01 - Crack growth in functionally graded materials and structures (Project Heads Kullmer, Gunter ;  Richard, Hans Albert ;  Specovius-Neugebauer, Maria )
• D02 - Analysis and effects of residual stresses in tools and components as a consequence of thermomechanical processes (Project Heads Scholtes, Berthold ;  Zinn, Wolfgang )
• D03 - Dämpfungsverhalten thermo-mechanisch gradierter Werkstoffe (Project Heads Göken, Jürgen ;  Steinhoff, Kurt )
• D04 - Fatigue behaviour of graded microstructures (Project Head Brückner-Foit, Angelika )
• D05 - Synthesis and multi-objective model-based optimisation of process chains for manufacturing parts with functionally graded properties (Project Heads Gräßler, Iris ;  Wagner, Tobias )
• D06 - Statistische Analyse des Ermüdungsverhaltens von gradierten Materialien (Project Heads Brückner-Foit, Angelika ;  Müller, Christine H. )
• MGK - Integrated Research Training Group (Project Head Wünsch, Olaf )
• Z - Central Tasks (Project Head Heim, Hans-Peter )

• Applicant Institution: Universität Kassel
• Co-Applicant Institution: Technische Universität Dortmund; Universität Paderborn
• Spokesperson: Professor Dr.-Ing. Hans-Peter Heim