Manufacturing industries such as the aerospace industry, the automotive industry, the shipbuilding industry, and the machine building industry are increasingly being driven by material property - oriented design requirements. These industries must deploy technologies, parts, components and systems that meet the strict regulations regarding the designs life on the one hand and can cope with requirements such as lower part weight and minimized resource consumption on the other.
To achieve these ambitious goals, new engineering disciplines have been developed with a multidisciplinary nature such as TPM (through process modeling) or ICME (Integrated Computational Materials Engineering).
In the above mentioned industries, at least on an OEM level, there are general standards and licensing procedures that apply to new technologies, new parts, new materials and also for the qualification of suppliers. A central aspect of such standards is the requirement for advanced virtual design, test tools and procedures.
Commercial simulation tools, such as those provided by Simufact, must therefore be developed and improved to meet all the requirements needed for correctly predicting material properties.
Through actively participating in research projects, we are ensuring that the industrial application of scientific knowledge does not become out of focus. The knowledge we gain from projects is used, whenever possible, to enhance our software functions as quickly as possible.
SupErLaTiv
Selective Laser Melting (SLM), also known as Laser Beam Melting (LBM), is one of the work horses of Additive Manufacturing (AM) technologies. Components are printed inside a build tank by successively adding thin layers of metal powder and selectively melting those areas of the powder layer that correspond to the part’s current cross-section.
Metal-based Laser Additive Manufacturing (LAM) technologies are capable of producing high performance parts with tremendous geometric complexity. The AM crash project will further develop this technology for the automotive sector for highly dynamic loaded applications. [nMetal-based Laser Additive Manufacturing (LAM) technologies are capable of producing high performance parts with tremendous geometric complexity. The AM crash project will further develop this technology for the automotive sector for highly dynamic loaded applications. bsp]
Additive manufacturing processes open new degrees of freedom with respect to product design in terms of shaping and application-specific optimized material properties.Thanks to product customization and product digitization, they offer great potential to revolutionize the manufacturing landscape.
Numerical Calculation of the die wear at industrial cold forming processes
As part of the Collaborative Research Area Transregio 73 "Sheet Metal Forming", a new sheet metal forming process has been developed in the subproject A7 at the Institute for Forming Technology and Forming Machines. Its process limits were extended by introducing an oscillation superposition in the machine's main flow.
The robust design & optimization of forming processes with bionic algorithms
The optimization of processes/process chains in the sense of being robust, low scatter process designs, by the appropriate parameter combinations derived from simulations, is still a new field of application. The reason for this can be found in the nonlinear nature of the processes to be examined and the multitude of variables influencing them. In the field of metal forming processes, long and complicated simulations are often necessary. This is due to the many different singular steps that need to be simulated with their related component parameters, tool geometries, material properties and then the interactions of the components and tools. Furthermore, numerous local maxima can be observed.
Project SiWEZAL: A short description (AiF Project number: KF2348405LF3)
The efficient determination of the time-temperature-property relations of thermally joined aluminum alloy components for numerical stress analyses
The thermal joining of aluminum alloys usually results in the degradation of local material properties. A reduction of strength related properties within the so-called "heat-affected zone" (HAZ) by a short-term topically focused transmission of heat is especially undesirable.
Project StrucSim: A short description (AiF Project number: KF2348403LF2)
The development of intelligent algorithms for generating microstructure-based flow-curve models for the simulating forming processes of lightweight construction materials
StrucSim is an innovative modeling approach for the simulation of microstructure effects developed by IBF, RWTH Aachen. Contrary to other established models, StrucSim not only incorporates the kinematics of recrystallization, but also gives predictions about the average grain size and statistical information about local grain size (minimum, maximum).
ICMEg – an ICME Expert group (EU support number: GA 606711)
ICME –Integrated Computational Materials Engineering - is an evolving engineering discipline that connects the physical and metallurgical considerations at different scales with computer-based process simulations.
DP Forge (Registered for support by the Federal Ministry of Education and Research under 01DQ14003A)
Combined Process and Alloy Design of a micro-alloyed DP Forging Steel based on Integrative Computational Material Engineering (DP Forge)
The goal of this project is to develop processes for the complex manufacturing procedures of forged components (e.g. gear wheels) made of a new DP steel created with an ICME tool with energy-optimized processes...
MANUELA Project has received funding from the European Union’s Horizon
MANUELA is the development and realization of a metal additive manufacturing (AM) pilot line service covering the full AM development cycle. This includes both simulation and the manufacturing process of AM covering the aspects of on-line process control, characterization, real-time feedback, post-treatment, AM qualification protocols and the associated business model.
The Bionic Aircraft Project has received funding from the European Union’s Horizon
The Bionic Aircraft project aims at transferring the maturity level of additive manufacturing (AM) to a resource efficient production process, significantly increasing the use of AM in civilian aircraft. In the medium term, advances in bionic design and material technology are set to lead to a weight reduction of up to 1 ton per aircraft. In the long term, the construction of completely new types of aircraft will be possible, with significant reduction of emissions during operation. The environmental impact is further reduced by the resource efficiency of the AM technologies giving rise to new possibilities of spare part logistics.
KRAKEN Project has received funding from the European Union’s Horizon
The Bionic Aircraft project aims at transferring the maturity level of additive manufacturing (AM) to a resource efficient production process, significantly increasing the use of AM in civilian aircraft. In the medium term, advances in bionic design and material technology are set to lead to a weight reduction of up to 1 ton per aircraft. In the long term, the construction of completely new types of aircraft will be possible, with significant reduction of emissions during operation. The environmental impact is further reduced by the resource efficiency of the AM technologies giving rise to new possibilities of spare part logistics.
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