SPP 1551:  Resource Efficient Constructional Elements

• Subject Area: Mechanical and Industrial Engineering
• Term: from 2011 to 2019
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 172488437

High power density and functional reliability are essential standards in technical products. Besides these demands sustainability issues get more and more into the focus of development activities. Especially high-energy efficiency, increased endurance life obtained by wear reduction and thus low resource consumption are matters of interest. In technical products functional requirements are mainly achieved by construction elements in which loads and torques are transmitted. These construction elements often work under conditions with relative movement of surfaces. Examples are gears, roller bearings, journal bearings, guide rails, piston-cylinder contacts or cam and follower contacts.
The intention of the Priority Programme is to develop optimal construction and design guide lines, manufacturing processes and running-in procedures with sustainability purposes aiming at providing minimised friction and lowest wear. In order to achieve these objectives, the following topics are examined: (1) optimisation of construction elements and their contact areas (geometry, topography, kinematics and material) with respect to minimised material input, friction and wear as well as recyclability of the materials; (2) definition and development of tribologically optimised running-in procedures;(3) development of an efficient running-in procedure for construction elements; (4) comprehension of mechanical, physical and chemical properties of boundary layers; (5) description and modelling of tribological contacts and boundary layer characteristics; (6) characterisation of the coherence of boundary layer properties and the tribological performance of construction element contacts.
The intention of the Priority Programme is to prepare guidelines and to describe methods for future component design (load, geometry, material and lubricant), component manufacturing (method, parameter, tools, cooling lubricant) and running-in procedures (time dependent load collective) for energy and resource efficient construction elements.

• DFG Programme: Priority Programmes

Projects

• Controlling of the friction in lubricated systems through Multi-Scale texturing with laser interference texturing and micro coining (Applicants Hirt, Gerhard ;  Mücklich, Frank )
• Coordination Funds (Applicant Höhn, Bernd-Robert )
• Einfluss kinematischer Modulationen beim Schleifen auf die Oberflächenstrukturierung zur Steigerung der Ressourceneffizienz von Zahnrädern (Applicants Popov, Valentin L. ;  Uhlmann, Eckart )
• Energy efficency improvement of timing chain drives (Applicant Sauer, Bernd )
• Entwicklung effizienter Einlaufmethoden zur Steigerung der Flankentragfähigkeit von Zahnrädern - experimentelle Untersuchung (Applicant Höhn, Bernd-Robert )
• Erhöhung des Wirkungsgrads von Getrieben durch den Einsatz generativ gefertigter, konturnah gekühlter Zahnräder (Applicant Reinhart, Gunther )
• High-strength gears produced by powder metallurgical processes (Applicants Broeckmann, Christoph ;  Klocke, Fritz )
• Increased rolling strength and friction reduction for bearings and homokinetic joints due to innovative hard machining (Applicants Denkena, Berend ;  Poll, Gerhard )
• Influence of triboinduced films on failures and frictional behaviour of gears with particular focus on running-in processes - experimental and analytical investigations (Applicants Kopnarski, Michael ;  Stahl, Karsten )
• Influence of triboinduced films on failures and frictional behaviour of gears with particular focus on running-in processes - simulations (Applicant Bartel, Dirk )
• Micro structure and run-in process influence on friction and wear intensity in the cam-tappet tribo-system including integral process and surface structuring developments (Applicants Ihlenfeldt, Steffen ;  Schwarze, Hubert )
• Optimization of the gear finishing process: Increase of the resource efficiency of boundary layers in the tooth flank contact (Applicant Brecher, Christian )
• Optimization of tribological systems by aimed anticipation of the running-in by final machining on the example of journal bearings (Applicants Albers, Albert ;  Scherge, Matthias ;  Schulze, Volker )
• Reactive boundary layers in metallic rolling contacts (Applicant Woydt, Mathias )
• Reduction of friction in EHD-contacts by microstructured surfaces of components: design, layout and manufacturing by forming (Applicants Merklein, Marion ;  Wartzack, Sandro )
• Resource-efficient ball screw by adaptive lubrication (Applicant Fleischer, Jürgen )
• Resource-efficient piston ring / cylinder liner-pairing (Applicants Bartel, Dirk ;  Karpuschewski, Bernhard )
• Use of thrust cone bearings to increase efficiency of helical gears (Applicant Lohrengel, Armin )
• Wear Protection in Roller Bearings due to Reaction Layer Formation at minimal Additive Concentration and Microtextured Surfaces (Applicants Gachot, Carsten ;  Jacobs, Georg )

• Spokesperson: Professor Dr.-Ing. Bernd-Robert Höhn
• Participating Persons: Professor Dr.-Ing. Albert Albers; Professor Dr.-Ing. Dirk Bartel; Professor Dr.-Ing. Christian Brecher; Professor Dr.-Ing. Christoph Broeckmann; Professor Dr.-Ing. Berend Denkena; Professor Dr.-Ing. Ludger Deters; Professor Dr.-Ing. Welf-Guntram Drossel; Professor Dr.-Ing. Jürgen Fleischer; Professor Dr.-Ing. Gerhard Hirt; Dr.-Ing. Hans-Werner Hoffmeister; Professor Dr.-Ing. Georg Jacobs; Professor Dr.-Ing. Bernhard Karpuschewski; Dr.-Ing. Hermann Kloberdanz; Professor Dr.-Ing. Fritz Klocke; Professor Dr. Michael Kopnarski; Professor Dr.-Ing. Dieter Krause; Professor Dr.-Ing. Armin Lohrengel; Professorin Dr.-Ing. Marion Merklein; Professor Dr.-Ing. Frank Mücklich; Professor Dr.-Ing. Gerhard Poll; Professor Dr. Valentin L. Popov; Professor Dr.-Ing. Gunther Reinhart; Professor Dr.-Ing. Bernd Sauer; Professor Dr.-Ing. Matthias Scherge; Professor Dr.-Ing. Volker Schulze; Professor Dr.-Ing. Hubert Schwarze; Professor Dr.-Ing. Karsten Stahl; Professor Dr.-Ing. Ralph Stelzer; Professor Dr.-Ing. Eckart Uhlmann; Professor Dr.-Ing. Thomas Vietor; Professor Dr.-Ing. Sandro Wartzack; Professor Dr.-Ing. Christian Weber; Dr.-Ing. Mathias Woydt; Professor Dr.-Ing. Michael Friedrich Zäh