Manufacture of defined residual stresses in friction assisted spinning and flow-forming

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The aim of the project is to expand the friction spinning process based on fundamental investigations concerning the manufacture of high-performance components for aviation and aerospace engineering with defined residual stress states. The locally adapted residual stress distributions generated in this way are to bring about an improvement in the quality and functionality of the parts, such as by allowing failure to be delayed or triggered in a defined manner, for example. The overall objective is therefore the adjustment of defined residual stress distributions over the entire and load-relevant area of the components to improve its quality and functionality. The research hypothesis being pursued is that residual stress distributions can be adjusted accurately, reproducibly and efficiently over the entire area of the components formed by friction-spinning of tubes, in particular by applying a model-based process control and that the constructive adaptation of the friction-spinning tool system and the associated expansion of the process parameter range and the spectrum of process strategies will create further possibilities for residual stress adjustments. The model-based process control adapted to the newly emerging process parameters is also intended to use the efficient and near-process 3D-DIC hole-drilling method. Furthermore, theoretical and numerical modelling of the residual stress generation in the friction spinning process is intended to replace the empirical modelling and will enable an even more efficient online control of the process. Finally, the manufactured components are to prove an improvement of the fatigue strength or the targeted failure under defined loading situations.