Development of multiaxially loaded structural elements for machine tools made of pre-stressed fiber-reinforced mineral casting suitable for production and loading using simulation-based design methods

• Applicants: Professor Dr.-Ing. Götz T. Gresser; Professor Dr.-Ing. Hans Christian Möhring
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering ; Engineering Design, Machine Elements, Product Development
• Term: since 2020
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 451783369

In the previous research project entitled "Improvement of the structural behavior of mineral cast components for use in machine tools through optimized preload design", it was empirically proven that the integration of prestressed carbon fiber rovings enables a significant improvement in the properties of mineral casting, particularly in terms of strength and stiffness. However, there is still a considerable need for research into the simulation-based design and construction of components made of prestressed fiber-reinforced mineral casting (VFMG). On the one hand, the residual stress field built up in the material is not characterized and therefore cannot be taken into account when dimensioning a structural component. On the other hand, the correlation between the material composition and the mechanical characteristics of the VFMG has not yet been explored. A design with material deviations from those previously investigated is therefore not possible. The aim of this research project is to generate well-founded findings that serve as a basis for the development of structural components made of VFMG. This includes the adaptation and parameterisation of the manufacturing process based on the simulation models developed for sophisticated, geometrically complex structures such as topology-optimised load-bearing structures. At the same time, the project aims to investigate the residual stress field and the correlation between material composition and mechanical properties in order to be able to predict mechanical properties for a well-founded design of structural components. For this purpose, in the first part of the project an analysis of the residual stress field resulting from the integration of the prestressed carbon fibers and an analysis of its structure is carried out. The findings are used in combination with the construction of a device for reproducible preload application to enable reproducible production of the test structures. Furthermore, empirical tests are carried out to implement a load-optimised material composition. The material properties determined in the tests are used together with the results from the previous project to develop a numerical model for the design of components made of VFMG. Finally, the results will be verified during the development, design, manufacture and testing of a structural component made of VFMG.

• DFG Programme: Research Grants