TRR 136:  Function Oriented Manufacturing Based on Characteristic Process Signatures

• Subject Area: Mechanical and Industrial Engineering ; Computer Science, Systems and Electrical Engineering ; Materials Science and Engineering ; Thermal Engineering/Process Engineering
• Term: from 2014 to 2022
• Website: Homepage
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 223500200

The research within the transregional Collaborative Research Center SFB/TRR 136 “Process Signatures” focusses on a mechanism-based analysis of workpiece surface layer modifications caused by manufacturing processes. As a main hypothesis it is assumed that the internal material load, characterized by process independent physical and chemical quantities, is responsible for the resulting material modifications. This mechanism-based view on manufacturing processes is scientifically new. It is expected that the results of the research work will enable a knowledge-based selection of necessary manufacturing processes and the corresponding parameters for the targeted chemical and physical properties of the workpiece surface layer. For this purpose the Collaborative Research Center introduces the notation “Process Signatures” and aims at demonstrating its potential for a broad range of manufacturing processes.The objective is to identify functional relationships between observed workpiece material modifications and the internal material loads during the manufacturing process. The research in the first funding period has shown that setting up Process Signatures is possible by the chosen approach. For the second funding period it is planned to take into account the influence of the workpiece material state before the manufacturing process on Process Signature components. Therefore, the research work will focus on multiple subsequent internal material loadings, caused by one manufacturing process and caused in a process chain, and their effect on the resulting material modifications. In the third funding period Process Signatures shall be utilized to predictively manufacture targeted functional properties of a component in a predictive approach. It is expected that the Collaborative Research Center will significantly contribute to the solution of the inverse problem when designing manufacturing processes.

• DFG Programme: CRC/Transregios
• International Connection: Switzerland

Current projects

• T02 - Using Process Signatures to unlock optimization potentials in process validations (Project Heads Karpuschewski, Bernhard ;  Sölter, Jens )
• T03 - Productivity increase in hard machining of steels based on Process Signatures (Project Heads Epp, Jérémy ;  Karpuschewski, Bernhard )
• T04 - Considering the influence of the strain rate in the design of processes with mechanical impact based on process signature components (Project Head Meyer, Daniel )
• T05 - Detection and avoidance of undesirable surface layer modifications in surface and profile grinding based on the causal sequence oriented approach of the process signature concept (Project Head Heinzel, Carsten )
• T06 - Data-based lifetime prediction for a function-oriented induction hardening process. (Project Heads Clausen, Brigitte ;  Lübben, Thomas )
• T07 - Development of the potential of mechanical material load during grinding by means of an novel tool concept (Project Heads Heinzel, Carsten ;  Meyer, Daniel )
• T08 - Load-oriented tool development for energy-supported diamond turning (Project Heads Karpuschewski, Bernhard ;  Riemer, Oltmann )

Completed projects

• 1 - Processes with mechanical main impact (Project Heads Garbrecht, Martin ;  Heinzel, Carsten ;  Meyer, Daniel )
• 1 - Processes with thermal main impact (Project Heads Klink, Andreas ;  Klocke, Fritz )
• 1 - Manufacturing processes with chemical main impact (Project Heads Klink, Andreas ;  Klocke, Fritz )
• 1 - Processes with thermo-mechanical impact in precision machining (Project Heads Brinksmeier, Ekkard ;  Karpuschewski, Bernhard ;  Riemer, Oltmann )
• 1 - Processes with thermo-mechanical impact – Finishing processes (Project Heads Brinksmeier, Ekkard ;  Heinzel, Carsten ;  Meyer, Daniel )
• 1 - Processes with thermo-chemical impact (Project Head Vollertsen, Frank )
• 1 - Processes with thermo-mechanical impact – finishing operations with geometrically defined cutting edge (Project Head Karpuschewski, Bernhard )
• 2 - Energy based process analysis for characteristic Process Signatures (Project Heads Brinksmeier, Ekkard ;  Karpuschewski, Bernhard ;  Lübben, Thomas ;  Sölter, Jens ;  Zoch, Hans-Werner )
• 2 - Thermomechanically coupled process modeling of microstructural material modifications (Project Heads Reese, Stefanie ;  Svendsen, Robert )
• 2 - Modelling of transport mechanisms for erosion processes (Project Heads Meinke, Matthias ;  Schröder, Wolfgang )
• 2 - Numerically efficient multiscale material models for processes with thermal and chemical impact (Project Heads Reese, Stefanie ;  Wulfinghoff, Stephan )
• 2 - Mechanism Analysis of Machining-Induced Chemical Material Modifications and their Effect on the Component Functionality (Project Head Zander, Daniela )
• 3 - Analysis of material modifications with diffraction methods (Project Heads Epp, Jérémy ;  Zoch, Hans-Werner )
• 3 - Analysis of materials modifications by high resolution microstructural characterisation (Project Head Mayer, Joachim )
• 3 - Measuring Material Loads with Material Integrated Sensors (Project Heads Goch, Gert ;  Lang, Walter )
• 3 - Areal optical measurement of mechanical material loadings (Project Head Fischer, Andreas )
• 4 - Contact Zone – Understanding Materials! (Project Heads Brinksmeier, Ekkard ;  Karpuschewski, Bernhard ;  Klocke, Fritz ;  Reese, Stefanie )
• 4 - Central tasks of the collaborative research center (Project Heads Brinksmeier, Ekkard ;  Karpuschewski, Bernhard )
• 4 - Material testing and heat treatment (Project Head Clausen, Brigitte )
• IIF04 - Processes with a thermo-mechanical impact - machining with geometrically defined cutting edges (Project Head Klocke, Fritz )
• IM02 - Mechanism analysis of material modifications caused by thermal and mechanical loads (Project Heads Clausen, Brigitte ;  Hoffmann, Franz )
• T01 - Functionality-based technology development in wire electrical discharge machining (Project Head Klink, Andreas )

• Applicant Institution: Universität Bremen
• Co-Applicant Institution: Rheinisch-Westfälische Technische Hochschule Aachen
• Participating Institution: BIAS - Bremer Institut für Angewandte Strahltechnik GmbH; Leibniz-Institut für Werkstofforientierte Technologien IWT
• Participating University: Oklahoma State University; School of Mechanical and Aerospace Engineering
• Spokespersons: Professor Dr.-Ing. Ekkard Brinksmeier, until 9/2019; Professor Dr.-Ing. Bernhard Karpuschewski, since 12/2019; Professorin Dr.-Ing. Stefanie Reese, from 10/2019 until 11/2019