Project Details
Projekt
Holistic process chain modeling for aluminum profile forming
Subject Area
Primary Shaping and Reshaping Technology, Additive Manufacturing
Term
since 2025
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 558590357
The project aims to develop a holistic modeling framework to simulate the manufacturing process chain of complex bent aluminum profiles, predicting critical-to-quality (CTQ) parameters and incorporating uncertainties. This will be the basis for optimizing process parameters across the entire production chain in the second phase, with a focus on achieving optimal CTQ targets: 1) springback, 2) wall thickness, 3) energy consumption during manufacturing, and 4) mechanical performance of the profile. The framework will ensure robustness against irreducible uncertainties and will provide guidance on efficiently minimizing reducible uncertainties. The process chain involves hot extrusion, forming of aluminum profiles and heat treatment, which are commonly used in industry for automotive applications, e.g., bumpers. Achieving global optimization of CTQs for the complete process chain remains elusive, as current process models are not designed to interface sequentially. Moreover, the presence of both reducible and irreducible uncertainties due to variable process conditions and material properties complicates achieving robust, reliable component production. The project tackles these challenges by developing robust and computationally efficient models capable of representing the entire production process holistically in a two-level modeling strategy. The first level involves using offline, physical white-box models to gain a deep understanding of the process chain and the interrelation of process parameters. The second level comprises of faster, more efficient, white-, grey-, and black-box models for real-time applications during production. This includes the development of new surrogate modeling approaches. The project is carried forward by three central objectives: 1) The identification of which stages or parameters in the production process critically affect the CTQs and the determination of whether these factors can be accurately predicted. Characterization of material properties and sensitivity analyses are essential components to determine the most influential factors and address their uncertainties; 2) The establishment of the process chain in the lab, and extensive experimental investigations to understand the interrelation of process parameters and their impact on the CTQ. Within this, the minimum number and type of sensors needed to detect significant changes in the process chain that impact the target properties will be established. These sensors are crucial for later enabling rapid adjustments based on the developed fast modeling approaches; 3) The enhancement of the robustness of the CTQ parameters under the irreducible uncertainties in the process. This involves incorporating and tracking interrelated uncertainties throughout the production process. Novel methods will be developed to quantify correlated and interdependent uncertainties, and to integrate them closely with the overall modeling framework to ensure reliable outcomes.
DFG Programme
Priority Programmes
