Development and Validation of a Heat Generation Model for Friction Press Joining
Final Report Abstract
FPJ offers unique possibilities for joining metals and plastic components. In order to enable this unique technology to be used for industrial purposes, process control is an important factor. In particular, force and temperature control are in the focus of science at this stage. It is noteworthy that these two variables influence each other and that the decisive temperature in the plastic component cannot be measured directly. This makes the model-based, indirect temperature control an indispensable approach. In this research project, a model-based, multivariable MPC was developed to control the forces and temperatures in the FPJ process. In addition, a 1D FD-model was elaborated, which allows the temperature in the plastic component to be calculated on the basis of the measurable surface temperature and to be controlled. The individual methods were published in the corresponding publications and were made accessible to the public. In addition, the transfer of the approaches and methods developed to other plastic-metal combinations was studied and evaluated. It was found that the model predictive control method, the transfer function design method, and the interfacial temperature calculation method are transferable and offer unique possibilities for process control. In addition, the FPJ technology was evaluated based on the obtained results and assessed with respect to an industrial application. This should ensure the transfer from science to industry. Furthermore, a proposal was developed to classify and categorize the FPJ process into the standard DIN 8580. Thus, the results of this research project contribute significantly to the industrialization and to a better understanding of the FPJ process.
Publications
- Influence of the laser-based surface modification on the bond strength for friction press joining of aluminum and polyethylene. Production Engineering 13 (2019) 6, pp. 721 – 730. ISSN: 0944- 6524
Meyer, S. P.; Wunderling, C.; Zaeh, M. F.
(See online at https://doi.org/10.1007/s11740-019-00926-y) - Design, evaluation, and implementation of a model-predictive control approach for a force control in friction stir welding processes. Production Engineering 14 (2020) 4, pp. 473 – 489. ISSN: 0944-6524
Meyer, S. P.; Bernauer, C. J.; Grabmann, S.; Zaeh, M. F.
(See online at https://doi.org/10.1007/s11740-020-00969-6) - A Holistic, Model-Predictive Process Control for Friction Stir Welding Processes Including a 1D FDM Multi-Layer Temperature Distribution Model. Metals 11 (2021) 3, 502
Meyer, S. P.; Fuderer, S.; Zaeh, M. F.
(See online at https://doi.org/10.3390/met11030502) - A Study on the Bond Strength of Plastic-Metal Direct Bonds Using Friction Press Joining. Metals 11 (2021) 4, 660
Meyer, S. P.; Herold, M. T.; Habedank, J. B.; Zaeh, M. F.
(See online at https://doi.org/10.3390/met11040660)
