Project Details
Projekt
Cross-process modelling of a cold forging and machining process chain of an impeller wheel with consideration of specific uncertainties
Subject Area
Primary Shaping and Reshaping Technology, Additive Manufacturing
Mechanical Properties of Metallic Materials and their Microstructural Origins
Metal-Cutting and Abrasive Manufacturing Engineering
Mechanical Properties of Metallic Materials and their Microstructural Origins
Metal-Cutting and Abrasive Manufacturing Engineering
Term
since 2025
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 558601144
In this research project, entitled ProMoKaZ, a process chain for manufacturing a compressor or an impeller wheel is being analysed, which comprises cold forging (impact extrusion) of a near-net-shape preform and its subsequent milling. The mechanisms of action and interactions of these indi-vidual processes are analysed by simulation and experiment in order to determine their influence on the final quality of the finished part. The aim of the applicants IFU and IFW at the University of Stuttgart is to develop an overall process chain for optimisation purposes by designing the individual processes appropriately and taking specific uncertainties into account. The novelty of the application lies in the establishment of a two-stage process sequence, which consists of a new type of cold pressing process and the machining of a geometrically demanding impeller geometry. Three optimisation goals are targeted by the researchers: Shape accuracy, surface quality and energy/ resource efficiency in the production of this component. In the first funding phase, the teams from both institutes will conceptually define the process chain and the individual processes and determine the boundary conditions. The virtual process chain will then be designed on the basis of a coherent programme system (DEFORM3D), which will initially be used to create FE models for both manufacturing processes. This is followed by the physical realization of the process chain on a laboratory scale at both institutes so that the numerical models can be validated experimentally. In this project phase, specific uncertainties of both manufacturing processes are characterised and their influence on the quality of the finished part is analysed. Established sensors and new soft sensors provide new quantities of information about process sequences and interactions between the subsequent processes so that the impact of the most sensitive process parameters can be explained. This requires surrogate models whose data spaces are created on the basis of FE calculations. In the second funding period, the inverse use of the surrogate models will be designed and coupled with algorithms for multi-criteria optimisation. The long-term goal of the project is the specification of the above-mentioned target variables of the impeller wheel and the automated determination of the correlating input and process variables of both manufacturing processes.
DFG Programme
Priority Programmes
