TRR 136:  Function Oriented Manufacturing Based on Characteristic Process Signatures

• Subject Area: Mechanical and Industrial Engineering ; Computer Science, Systems and Electrical Engineering ; Materials Science and Engineering ; Thermal Engineering/Process Engineering
• Term: from 2014 to 2022
• Website: Homepage
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 223500200

• Final Report Year: 2023

Final Report Abstract

The research object of the SFB/TRR 136 "Function-Oriented Manufacturing on the Basis of Characteristic Process Signatures" was the mechanism-oriented analysis of the relationships between manufacturing processes and the material modifications they cause in the workpiece surface layer. The basic assumption of the SFB/TRR 136 was that the internal material load prevailing in the material during a manufacturing process is responsible for its reaction in the form of a modification. This mechanism-oriented approach made it possible to select and adjust exemplary manufacturing processes and process chains in a knowledge-based manner with regard to the desired surface layer properties of the workpiece (solution of the inverse problem in manufacturing). As the core of the new approach, the SFB/TRR 136 introduced Process Signatures as a decisive insight, which represent the connection between internal material load and modification. The research work demonstrates the potential of Process Signatures for a wide range of manufacturing processes. The recurring internal material loads, for example due to a renewed tool contact, which usually occur in industrial manufacturing processes, were also taken into account. Furthermore, it could be shown that a changed initial state of the workpiece surface layer due to multiple internal material loads caused by a previous process step or another process can significantly influence the mechanisms taking place and the material modifications occurring. This knowledge can be utilized for an advantageous process (chain) design. A further development of the Process Signature approach is seen in functionoriented manufacturing. This means the targeted selection and adjustment of manufacturing processes and process chains on the basis of specified functional properties of a component. This is a task that requires further research efforts and shall be addressed in transfer projects of the SFB/TRR 136, among others.

Publications

• Process Signatures – A New Approach to Solve the Inverse Surface Integrity Problem in Machining Processes. Procedia CIRP, 13, 429-434.
  Brinksmeier, Ekkard; Klocke, Fritz; Lucca, Don A.; Sölter, Jens & Meyer, Daniel
  
• Interdisciplinary modelling of the electrochemical machining process for engine blades. CIRP Annals, 64(1), 217-220.
  Klocke, F.; Zeis, M. & Klink, A.
  
• Modeling nanostructural surface modifications in metal cutting by an approach of thermodynamic irreversibility: Derivation and experimental validation. Continuum Mechanics and Thermodynamics, 29(1), 271-289.
  Buchkremer, S. & Klocke, F.
  
• Steel integrated thin film sensors for characterizing grinding processes. Sensors and Actuators A: Physical, 242, 203-209.
  Dumstorff, Gerrit; Sarma, Mridusmita; Reimers, Marcel; Kolkwitz, Benjamin; Brinksmeier, Ekkard; Heinzel, Carsten & Lang, Walter
  
• Two-scale FE–FFT-and phase-field-based computational modeling of bulk microstructural evolution and macroscopic material behavior. Computer Methods in Applied Mechanics and Engineering, 305, 89-110.
  Kochmann, Julian; Wulfinghoff, Stephan; Reese, Stefanie; Mianroodi, Jaber Rezaei & Svendsen, Bob
  
• Compilation of a thermodynamics based process signature for the formation of residual surface stresses in metal cutting. Wear, 376-377, 1156-1163.
  Buchkremer, S. & Klocke, F.
  
• Efficient and accurate two-scale FE-FFT-based prediction of the effective material behavior of elasto-viscoplastic polycrystals. Computational Mechanics, 61(6), 751-764.
  Kochmann, Julian; Wulfinghoff, Stephan; Ehle, Lisa; Mayer, Joachim; Svendsen, Bob & Reese, Stefanie
  
• Surface integrity in precision turning of steel. The International Journal of Advanced Manufacturing Technology, 94(1–4), 763–771.
  Willert, Melanie; Riemer, Oltmann & Brinksmeier, Ekkard
  
• Correlations between Thermal Loads during Grind-Hardening and Material Modifications Using the Concept of Process Signatures. Journal of Manufacturing and Materials Processing, 2(1), 20.
  Kolkwitz, Benjamin; Kohls, Ewald; Heinzel, Carsten & Brinksmeier, Ekkard
  
• Development of a Process Signature for Manufacturing Processes with Thermal Loads. Metallurgical and Materials Transactions A, 49(8), 3419-3429.
  Frerichs, Friedhelm; Meyer, Heiner; Strunk, Rebecca; Kolkwitz, Benjamin & Epp, Jeremy
  
• Fluid structure interaction of thin graphite electrodes during flushing movements in sinking electrical discharge machining. CIRP Journal of Manufacturing Science and Technology, 20, 23-28.
  Klocke, F.; Zeis, M. & Heidemanns, L.
  
• In Situ X-ray Diffraction Analysis of Stresses during Deep Rolling of Steel. Quantum Beam Science, 2(4), 20.
  Meyer, Heiner & Epp, Jérémy
  
• Mechanisms and processing limits of surface finish using laser-thermochemical polishing. CIRP Annals, 67(1), 201-204.
  Eckert, Sandro & Vollertsen, Frank
  
• Precise In-Process Strain Measurements for the Investigation of Surface Modification Mechanisms. Journal of Manufacturing and Materials Processing, 2(1), 9.
  Tausendfreund, Andreas; Stöbener, Dirk & Fischer, Andreas
  
• Process Signatures -The Missing Link to Predict Surface Integrity in Machining. Procedia CIRP, 71, 3-10.
  Brinksmeier, E.; Meyer, D.; Heinzel, C.; Lübben, T.; Sölter, J.; Langenhorst, L.; Frerichs, F.; Kämmler, J.; Kohls, E. & Kuschel, S.
  
• Underlying Mechanisms for Developing Process Signatures in Manufacturing. Nanomanufacturing and Metrology, 1(4), 193-208.
  Brinksmeier, E.; Reese, S.; Klink, A.; Langenhorst, L.; Lübben, T.; Meinke, M.; Meyer, D.; Riemer, O. & Sölter, J.
  
• The Right Signature for Every Process. German Research, 41(2), 26-29.
  Brinksmeier, Ekkard; Reese, Stefanie & Sölter, Jens
  
• Comparison of Different Manufacturing Processes of AISI 4140 Steel with Regard to Surface Modification and Its Influencing Depth. Metals, 10(7), 895.
  Borchers, Florian; Clausen, Brigitte; Eckert, Sandro; Ehle, Lisa; Epp, Jeremy; Harst, Simon; Hettig, Matthias; Klink, Andreas; Kohls, Ewald; Meyer, Heiner; Meurer, Markus; Rommes, Bob; Schneider, Sebastian & Strunk, Rebecca
  
• Development of a process signature for electrochemical machining. CIRP Annals, 69(1), 153-156.
  Bergs, Thomas & Harst, Simon
  
• Development of surface residual stress and surface state of 42CrMo4 in multistage grinding. Procedia CIRP, 87, 198-203.
  Borchers, Florian; Meyer, Heiner; Heinzel, Carsten; Meyer, Daniel & Epp, Jérémy
  
• Electron microscopic characterization of surface zones thermo-chemically modified by electrical discharge machining. Journal of Materials Processing Technology, 280, 116596.
  Ehle, L.C.; Schneider, S.; Schwedt, A.; Richter, S.; Klink, A. & Mayer, J.
  
• A novel approach for the efficient modeling of material dissolution in electrochemical machining. International Journal of Solids and Structures, 229, 111106.
  van der Velden, Tim; Rommes, Bob; Klink, Andreas; Reese, Stefanie & Waimann, Johanna
  
• An Investigation on High-Resolution Temperature Measurement in Precision Fly-Cutting. Sensors, 21(4), 1530.
  Gräbner, Daniel; Zielinski, Tjarden; Vovk, Andrey; Riemer, Oltmann; Karpuschewski, Bernhard & Lang, Walter
  
• Analysis of internal material loads and Process Signature Components in deep rolling. CIRP Journal of Manufacturing Science and Technology, 35, 400-409.
  Kinner-Becker, Tobias; Hettig, Matthias; Sölter, Jens & Meyer, Daniel
  
• Change of Oxidation Mechanisms by Laser Chemical Machined Rim Zone Modifications of 42CrMo4 Steel. Materials, 14(14), 3910.
  Schupp, Alexander; Pütz, René Daniel; Beyss, Oliver; Beste, Lucas-Hermann; Radel, Tim & Zander, Daniela
  
• Comparison of Process Signatures for thermally dominated processes. CIRP Journal of Manufacturing Science and Technology, 35, 217-235.
  Karpuschewski, B.; Lübben, Th.; Meinke, M.; Eckert, S.; Frerichs, F.; Schneider, S.; Klink, A.; Langenhorst, L. & Sölter, J.
  
• Direct particle–fluid simulation of flushing flow in electrical discharge machining. Engineering Applications of Computational Fluid Mechanics, 15(1), 328-343.
  Brito, Gadeschi Gonzalo; Schilden, Thomas; Albers, Marian; Vorspohl, Julian; Meinke, Matthias & Schröder, Wolfgang
  
• Efficient two-scale FE-FFT-based mechanical process simulation of elasto-viscoplastic polycrystals at finite strains. Computer Methods in Applied Mechanics and Engineering, 374, 113566.
  Gierden, Christian; Kochmann, Julian; Waimann, Johanna; Kinner-Becker, Tobias; Sölter, Jens; Svendsen, Bob & Reese, Stefanie
  
• Evaluation of Hardness and Residual Stress Changes of AISI 4140 Steel Due to Thermal Load during Surface Grinding. Journal of Manufacturing and Materials Processing, 5(3), 73.
  Kohls, Ewald; Heinzel, Carsten & Eich, Marco
  
• In-Process Measurement of Three-Dimensional Deformations Based on Speckle Photography. Applied Sciences, 11(11), 4981.
  Tausendfreund, Andreas; Stöbener, Dirk & Fischer, Andreas
  
• Influence of multi-pass laser hardening of normalized AISI 4140 on the grain size. Surface and Coatings Technology, 421, 127434.
  Lu, Yang; Ehle, Lisa C.; Richter, Silvia & Radel, Tim
  
• Influence of Subsequently Applied Mechanical and Thermal Loads on Surfaces Ground with Mechanical Main Impact. Materials, 14(9), 2386.
  Strunk, Rebecca; Borchers, Florian; Clausen, Brigitte & Heinzel, Carsten
  
• Modelling and Simulation of Mechanical Loads and Residual Stresses in Deep Rolling at Elevated Temperature. Journal of Manufacturing and Materials Processing, 5(3), 76.
  Kuschel, Sven; Kinner-Becker, Tobias; Zmich, Robert; Sölter, Jens & Meyer, Daniel
  
• Noise reduction in high-resolution speckle displacement measurements through ensemble averaging. Applied Optics, 60(7), 1871.
  Schweickhardt, León; Tausendfreund, Andreas; Stöbener, Dirk & Fischer, Andreas
  
• Numerical investigation of the influence of multiple loads on material modifications during hard milling. Procedia CIRP, 102, 500–505.
  Vovk, Andrey; Sölter, Jens & Karpuschewski, Bernhard
  
• Oxide Formation during Transpassive Material Removal of Martensitic 42CrMo4 Steel by Electrochemical Machining. Materials, 14(2), 402.
  Zander, Daniela; Schupp, Alexander; Beyss, Oliver; Rommes, Bob & Klink, Andreas
  
• The Influence of Former Process Steps on Changes in Hardness, Lattice and Micro Structure of AISI 4140 Due to Manufacturing Processes. Metals, 11(7), 1102.
  Borchers, Florian; Clausen, Brigitte; Ehle, Lisa C.; Eich, Marco; Epp, Jérémy; Frerichs, Friedhelm; Hettig, Matthias; Klink, Andreas; Kohls, Ewald; Lu, Yang; Meyer, Heiner; Rommes, Bob; Schneider, Sebastian; Strunk, Rebecca & Zielinski, Tjarden
  
• Development of a process signature for electrical discharge machining. CIRP Annals, 71(1), 177-180.
  Klink, Andreas; Schneider, Sebastian & Bergs, Thomas
  
• Process Signatures–Knowledge-based approach towards function-oriented manufacturing. Procedia CIRP, 108, 624-629.
  Karpuschewski, B.; Kinner-Becker, T.; Klink, A.; Langenhorst, L.; Mayer, J.; Meyer, D.; Radel, T.; Reese, S. & Sölter, J.