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    Investigation of the transferability of the fatigue behaviour of fibre-reinforced plastics from coupon samples to optimised higher-level components for the development of a design guideline
    Effective and reliable product development methods for fibre-plastic composites (FRP) allow a high degree of exploitation of lightweight design potential, as safety factors can be reduced due to a better understanding of the interactions and a precise knowledge of the distribution of influencing factors. In the present research project, a method for the consideration of the fatigue behaviour of FRP in the design is to be conceived, implemented and evaluated, which on the one hand considers the special features of optimised layer structures and on the other hand the influence of material and structural uncertainties on the fatigue behaviour. The method considers the scatter of the influencing factors and enables the product developer to create robust designs. It is based on detailed experimental investigations on different levels of the test pyramid, from which conclusions are drawn about suitable design limits for the determination of the FRP fatigue behaviour, and also quantifies occurring distributions of individual influencing parameters. Starting with coupon samples, the results are successively transferred to the semi-finished product level, considering any uncertainties that may occur. A further focus lies on the optimisation of the force introduction points. After comprehensive evaluation, the findings will be transferred to software tools, which should increase the acceptance of lightweight FKV construction methods among users. Finally, two different demonstrator concepts will be derived, manufactured and tested jointly by the two applicants based on the developed method and knowledge base. Based on these results, the method will be evaluated and further potentials will be shown.
      37
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    Schleifen präziser Oberflächen rotierender Leichtbaukomponenten zur Ressourceneffizienz in E-Mobility und Maschinenbau
    Die Fertigung hochpräziser Faserverbundbauteile bildet die Grundlage für nachhaltige und energieeffiziente Antriebskomponenten aus Faser-Kunststoff-Verbund (FKV), die sowohl bei der Herstellung als auch in der Nutzungsphase signifikante Ressourcen- und CO2-Einsparungen ermöglichen. Zentrale Herausforderungen bei FKV-Komponenten sind die Lagerung rotierender Komponenten im Fertigungsprozess, die Ausführung hochpräziser Schnittstellen zu weiteren Antriebskomponenten und sehr enge Bauteiltoleranzen. Ziel des Projekts ist es, die Voraussetzungen für serientaugliche Schleifprozesse hochpräziser Faserverbundbauteile zu schaffen, um die breite industrielle Anwendung von FKV in ressourcenschonenden Antriebskomponenten (Maschinenbau, Automotive, Aviation) zu ermöglichen. Der Fokus des IPMT-Institutes der TU Hamburg liegt dabei auf der Erarbeitung grundlegender Zusammenhänge beim Präzisionsschleifen von FKV abhängig von Werkstück- und Schleifwerkstoff und deren Auswirkungen auf Oberflächenqualität, Maß- und Formtoleranz sowie Ressourceneffizienz. Mit grundlegenden Erkenntnissen der Zerspanbarkeit wird die Basis geschaffen, FKV-Leichtbauteile vielfältiger Geometrien für verschiedene Anwendungen präzise, zielgerichtet, prozesssicher und ressourcenschonend herzustellen. Als Zerspanbarkeitskenngrößen werden Zerspankräfte, -temperaturen, Werkzeugverschleiß, Qualitätsmerkmale sowie Abtragsprodukte zunächst in grundlegenden Umfang-Längs-Plan-Schleifprozessen experimentell untersucht und empirisch modelliert. Auf dieser Basis werden anwendungsgerechte Schleifprozesse entwickelt sowie die Ressourcen- und Energieverbräuche der Schleifprozesse in einer CO2-Bilanz erfasst. Das Projektziel des PKT-Institutes der TU Hamburg ist es, ein vertieftes Verständnis des Reibungs- und Verschleißverhaltens von hochbelasteten FKV-Oberflächen am Beispiel der Hohlschaftkegel-Werkzeugaufnahme (HSK) einer FKV-Werkzeugspindel zu erlangen. Hierfür wird ein anwendungsnaher Tribologieprüfstand entwickelt und in Betrieb genommen. An diesem werden Reib- und Verschleißversuche an gewickelten Testkörpern mit unterschiedlichen Laminaten unter verschiedenen Bedingungen durchgeführt. Hierbei ist insbesondere die Bestimmung von Reib- und Verschleißbeiwerten in Abhängigkeit von Einflussparametern wie Oberflächengüte, Wickelparameter, Schleif-, Kühl- und Schmierverfahren von Interesse, um die Auswirkungen der Schleifprozessgestaltung auf das tribologische Verhalten der Oberflächen zu verstehen. Anhand eines Prüfstandes für HSK-Aufnahmen wird die Übertragbarkeit der Ergebnisse der vorangegangenen, abstrahierten Versuche auf den konkret betrachteten Anwendungsfall nachgewiesen. Auf Grundlage der Untersuchungen werden Gestaltungsempfehlungen für verschleißbelastete Welle-Nabe-Schnittstellen erstellt.
      48  8
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    Experimental investigation and probabilistic analysis of the load carrying capability of cylindrical shells subject to multiaxial loading
    The load carrying capability of axially loaded cylindrical shells is mainly driven by deviations from the ideal geometry and load application. Therefore, a multitude of publications suggest probabilistic design approaches in order to account for the stochastic imperfection for the design of cylindrical shells. For other types of loading like torsion and bending the load carrying capability is less sensitive. The distribution of the buckling load for these types of loading and especially for combined loading has not been investigated so far. The objective of this research project is to determine the stochastic distribution of the load carrying capability of cylindrical shells subject for various load combinations. This will be done by buckling experiments and probabilistic simulations. Based on the results, a probabilistic design approach for multiaxially loaded cylindrical shells will be developed. The investigations will be carried out for combinations of axial compression and torsion as well as axial compression and bending. In order to investigate the influence of slenderness and anisotropy, fibre composite cylinders as well as stiffened and unstiffened isotropic cylinders will be tested and analysed.
      120
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    SPP 2305: Microelectronic modular system for sensor-integrating machine elements
    The systematic development of sensor-integrating machine elements (SiME), in particular taking into account the severely limited installation space, efficient data management and a self-sufficient energy budget, represents a significant challenge in the field of mechatronic development that is currently not sufficiently supported methodologically. The aim of this project is to design and test a model-based microelectronic modular system for the systematic development of sensor systems in SiME, using the example of fixing and motion screws, in order to be able to configure and predefine application-specific sensor systems from electronic modules. This is to be achieved through the necessary collaboration between the different areas of mechanics, (micro-) electronics, software and design methodology.At the beginning, mechanical, electrical and geometrical requirements for sensor systems in sensor-integrating fixing and motion screws are identified. These are implemented in a requirements model in the modelling language SysML as the basis for the model-based microelectronic modular system. Subsequently, the product characteristics necessary to fulfil the requirements are determined. Available microelectronic components are subsequently identified, analysed with regard to their properties and a suitable structure for their classification is developed. The components are modelled in SysML with the associated dependencies and the necessary parameters for configuration and predesign as a microelectronic modular system. This type of modelling makes it possible to store different types of data elements and allows a simple consistency check in the case of later adjustments as well as the extension of the microelectronic modular system. If the modular structure is transferred to a suitable configuration system, it allows the application-specific combination of module variants and the configuration of different solution alternatives for sensor systems in SiME. This is done taking into account the respective requirements from the measurement task and the individual application and boundary conditions of the machine element. The system configuration and design is based on three newly defined basic strategies: optimised for data-, energy- or installation space. Two sensor systems are selected as examples for prototypical implementation in the form of demonstrators. For an initial verification of the model based modular system and the configuration system, the prototypically realised sensor system demonstrators will each be integrated into a fixing and a motion screw. Finally, the realised SiME prototypes will be experimentally examined in static and dynamic tests to enable a comparison between the measured and predicted signals and application limits of the sensor systems.
      115
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    Methodical Framework for the Development of Customer-Specific Product Families based on Modular Product Structures
    The megatrend of individualization requires manufacturing companies to improve the fulfillment of customer-specific requirements by their products, which will increase the success of a company, for example through competitive advantages or better customer loyalty. However, increasing external variety goes hand in hand with increased internal variety. The advantages of differentiation are offset by the increase in variant-induced complexity, which leads to higher costs overall - especially the so-called complexity costs. The only way to counteract this is to adopt the opposite strategy of standardization, which, however, does not allow products to be further differentiated or even individualized. While the development of modular product architectures already overcomes methodically variant-induced complexity for variant-rich products in the conflict between standardization and differentiation, the ideal fulfillment of customer requirements is still likely to be oversized, when completely predefined product variants are considered. Customer-specific product adaptation as a solution strategy for reducing oversizing is considered in the literature, but so far it has been considered in isolation and without any connection and integration as a possible solution strategy in the design of modular product architectures. The tension between standardization and differentiation thereby reaches a further level of consideration, where not only a decision for a standardized or variant solution must be made, but also a consideration between variant design or a design exactly adapted to customer-specific requirements. Up to now, there is no consistent methodical support for this in the literature.At this point, this project starts by developing a method that supports the design of modular product structures with customer specific modules and thus further develops the modular product architecture to a modular-customized product architecture in order to avoid oversizing in an idealized way. In the consideration of modular product architectures, which are subject to the conflicting efforts of standardization vs. differentiation, this project adds the new, contradictory efforts between differentiation vs. individualization. The new method will be developed and tested using product examples with sufficient data of other research projects.
      109