Project Details
Projekt
Property-controlled forging: analysis and experimental validation
Subject Area
Primary Shaping and Reshaping Technology, Additive Manufacturing
Term
since 2019
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 424334423
In isothermal forging, the tools are heated to the workpiece temperature, so that near-net-shaping becomes feasible for materials of low workability. Advances in isothermal forging have recently made it possible to use turbine blades made of intermetallic titanium aluminides (TiAl) in serial production in commercial jet engines. Currently, however, many limitations of this technology can be found due to the high demands on final geometry as well as the demand on the high degree of deformation of the cast structure. With the current process and tooling technology, the material utilization of turbine blades is often less than 10%. In phase 1, a property-controlled isothermal flat tool forging process with local forming was therefore investigated and a suitable controller has been derived. In the 2nd phase we focused on property-controlled flat tool forging in several strokes using local heating of the workpiece. Suitable control strategy using a Level-Set description of the deformed geometry has been proposed and analysed. In the third phase the joint and robust control of target geometry as well as deformation degree under controls of multiple strokes will be our focus. The part of the proposal led by M. Bambach focusses on the prediction of the material micro-structure using surrogate models based on neural networks. Those allow to be used as real-time soft-sensors under near-production conditions. It is planned to achieve the joint prediction of target geometry and deformation degrees, such that tools can be produce for the final production process step. The part of the proposal lead by M. Herty investigates the mathematical aspects of robust controllers based on verifiable surrogate soft-sensors given by the trained neural networks. A formulation using Bayes’s theorem for the design of novel controls with error guarantees will be developed. The research questions in forming, geometry, microstructure control and mathematical control theory are closely linked in various aspects.
DFG Programme
Priority Programmes
Subproject of
SPP 2183:
Property-controlled metal forming processes
