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

该项目的目标是在有关航空航天工程高性能部件制造的基础研究的基础上，扩大摩擦旋压工艺，以确定残余应力状态。以这种方式产生的局部适应的残余应力分布将带来部件的质量和功能的改进，例如通过允许以定义的方式延迟或触发故障。因此，总体目标是调整部件整个和与载荷相关的区域上定义的残余应力分布，以改善其质量和功能。正在进行的研究假设是，通过应用基于模型的工艺控制，尤其是通过应用基于模型的工艺控制，可以准确、可重复和有效地调整通过管材摩擦旋压形成的部件的整个区域上的残余应力分布，并且摩擦旋压工具系统的建设性调整以及工艺参数范围和工艺策略范围的相关扩展将为残余应力调节创造更多的可能性。与新出现的工艺参数相适应的基于模型的工艺控制也是为了使用高效和接近工艺的3D-DIC打孔方法。此外，摩擦旋压过程中残余应力产生的理论和数值模拟旨在取代经验模型，并将使得能够更有效地在线控制该过程。最后，制造的部件要证明在规定的加载情况下疲劳强度或目标失效的改善。

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.