Weiterentwicklung des Digitalen Prototyps zum Digitalen Fingerabdruck

Durch die stark zunehmende Digitalisierung wird das Produkt immer stärker mit der Produktion und dem In-Service-Bereich gekoppelt. Dies unterstützt die Automatisierung vieler Herstellprozesse und ermöglicht eine lückenlose Rückverfolgung eines jeden Bauteils bis hin zum Material. Im Forschungsprojekt Digitaler Fingerabdruck des Forschungscampus ARENA2036 wird in Zusammenarbeit von verschiedenen Instituten und Firmen diese Kopplung an einem Demonstrator ausgeführt und die erforderlichen Schnittstellen und Datenflüsse generiert

Simulation supported manufacturing of profiled composite parts using the braiding technique

Composite materials have brought new development and sizing possibilities for structural components in transportation systems. Their high specific material properties are enabling weight reduction while increasing structural performance. On the downside, composite materials are generally related to high material and manufacturing costs and increased characterization efforts. Through the braiding technique, profiled structures can be manufactured in a highly automated and reproducible process. Moreover, braided composites can absorb more energy compared to their unidirectional or woven counterparts. In this paper, we describe the development and validation of a simulation framework as sustainable alternative to material- and cost-intensive experimental testing. Our work aims at considering the influence of manufacturing effects and textile architecture on the material properties and therefore at increasing the reliability of structure sizing. As validation basis, flat specimens of biaxial and triaxial braided composites are first manufactured and tested under quasi-static loading. We then develop a digital twin of the braiding process and its material characterisation. Within this framework, the braid’s textile architecture is predicted with multiple finite-element simulations at the mesoscopic scale. The numerical predictions show the strong influence of braiding angle and braiding core diameter on the textile architecture and consequently on the material properties. More particularly, crucial effects with negative impact on the mechanical properties (presence of gaps or yarn locking) are highlighted. On a pure numerical basis, we finally calculate the process window for braided structures, which links the process parameters to the resulting material properties. The present approach is a crucial step toward the reduction of experimental investigations in early development

Numerische Prozesskette für die Auslegung von geflochtenen Fahrzeugkomponenten – Nutzen und Herausforderungen

Teil des Forschungscampus ARENA2036 ist das Projekt DigitPro – Digitaler Prototyp. Entwickelt wird hier eine geschlossene, numerische Prozesskette zur Auslegung und Optimierung von textilbasierten Bauteilen. Ziel ist es, den realen Produktentstehungsprozess zu unterstützen, sowie die Entwicklungszeiten- und Kosten zu reduzieren. Ein verlustfreier Datenaustausch wird durch die Nutzung eines HDF5-Formats und durch die Definition einer projektspezifischen Dateistruktur gesichert. Am Beispiel eines geflochtenen Bauteils wird das Potenzial der Prozesskette in diesem Beitrag veranschaulicht

DigitPro – Digital Prototype Build-up Using the Example of a Braided Structure

In this study, the development of a digital prototype on the example of a braided structure is presented. The different fields of engineering which have been considered are material design, manufacturing (braiding simulation & virtual infiltration) as well as structural analysis. Main goal of the digital prototype is to connect the various input- and output files of the software tools, to establish a user-friendly readability via a neutral, binary HDF5 file format as well as decreasing the cycle time during product design. On the basis of the example geometry a braiding mandrel concept was developed. A subsequent braiding simulation provided the fibre placement, the fibre orientations and the braiding path, which was transferred to a KUKA robot via a CAM interface for the actual manufacturing process. The braided structures were analysed with an automatic 3D preform analysis system, a 3D Measuring System (GOM ATOS Triple Scan) and CT-scans. The results were used for the virtual infiltration and for preform models, build with TexGen. These simulations were validated with experimental vacuum infusion tests, section cut specimen, ashing specimen and tensile coupon specimen

Digitaler Prototyp Ganzheitlicher digitaler Prototyp im Leichtbau für die Großserienproduktion

Mitte 2018 und nach fünf Jahren Forschungszeit kommt eines der drei technischen Startprojekte der ARENA2036 zum Ende. Zu diesem Anlass und als Projektabschluss sollen Forschungsergebnisse aus dem Projekt DigitPro vorgestellt werden. Der Digitale Prototyp stellt das Bindeglied zwischen klassischen Ingenieurstätigkeiten und der Industrie 4.0 dar. Bauteilauslegungen und Prozesssimulationen werden vor der realen Fertigung durchgeführt und Optimierungsschleifen durchgeführt. Dies führt zu kürzeren Entwicklungszeiten und schont Ressourcen. Eine integrierte CAM-Schnittstelle ermöglicht den Datenübertrag an ausführende Produktionseinheiten wie Roboter, Flechtmaschinen oder Injektionspressen. Zusätzlich dient der Digitale Prototyp als Fertigungsprotokoll, in dem alle anfallenden Daten erhoben und für spätere Optimierungsschleifen oder Qualitätssicherungsmaßnahmen abgespeichert werden. In dieser Veröffentlichung werden die notwendigen Schritte zur Realisierung eines Digitalen Prototyps aufgezeigt sowie Forschungsergebnisse der einzelnen Disziplinen (virtuelle Materialmodellierung, Prozesssimulation, Datenstrukturen und digitale Auslegung) im Detail erläutert. Ein Fokus stellt hierbei die Multi-Skalen-Simulation von faserverstärkten Bauteilen dar

Relation between soil organic matter and yield levels of nonlegume crops in organic and conventional farming systems

The aim of this study was to evaluate the interaction between yield levels of nonleguminous crops and soil organic matter (SOM) under the specific conditions of organic and conventional farming, respectively, and to identify implications for SOM management in arable farming considering the farming system (organic vs. conventional). For that purpose, correlations between yield levels of nonlegume crops and actual SOM level (Corg, Nt, Chwe, Nhwe) as well as SOM-level development were examined including primary data from selected treatments of seven long-term field experiments in Germany and Switzerland. Yield levels of nonlegume crops were positively correlated with SOM levels, but the correlation was significant only under conditions of organic farming, and not with conventional farming treatments. While absolute SOM levels had a positive impact on yield levels of nonlegumes, the yield levels of nonlegumes and SOM-level development over time correlated negatively. Due to an increased demand of N from SOM mineralization, higher yield levels of nonlegumes obviously indicate an increased demand for OM supply to maintain SOM levels. Since this observation is highly significant for farming without mineral-N fertilization but not for farming with such fertilization, we conclude that the demand of SOM-level maintenance or enhancement and thus adequate SOM management is highly relevant for crop production in organic farming both from an agronomical and ecological point of view. Under conventional management, the agronomic relevance of SOM with regard to nutrient supply is much lower than under organic management. However, it has to be considered that we excluded other possible benefits of SOM in our survey that may be highly relevant for conventional farming as well