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Project B10: Simulation of the distortion potential of thin-walled components with internal residual stress during machining

Person in Charge: M.Sc. Andreas Fellmeth
  Motivation
One of the goals of the Research Training Group is the development of simulation methods for the description, evaluation and optimization of component conditions for process chains “from semi-finished to finished components“.  The process chains in sheet metal component manufacturing and process chains for solid components are considered. Solid components are processed by soft machining, case hardening and hard machining and sheet metal components by rolling, deep drawing and press hardening. These processing steps and the subsequent machining lead to residual stresses and distortion. The inheritance of component properties as a function of the upstream processing steps plays an important role. The aim of this project is to use simulations to predict the distortion due to the residual stress on the entire component and to develop compensation strategies.
 
Research Aims
  • FE-modeling of machining processes in 2D considering components conditions linking to adjacent sub production chain
  • FE-modeling of machining processes in 3D
    Simulations study of the process parameters considering different initial states
  • Analysis of the geometry change using a replacement model
  • Simulative prediction of distortion release during machining as a function of upstream sub-processes (case-, induction- and press hardening)
  • Development of compensation (strategies) for  optimal distortion hard machining