Sensitivity of process signals to deviations in material distribution and material properties of hybrid workpieces

authored by: Berend Denkena, Bernd Arno Behrens, Ludger Overmeyer, Stefan Kaierle, Benjamin Bergmann, Heinrich Klemme, Jörg Hermsdorf, Malte Stonis, Nick Schwarz, Laura Budde, Paulina Merkel, Miriam Handrup
Abstract: Hybrid components, made of multiple materials, can meet the increasing demands for lightweight construction and functional integration in the automotive and aircraft industry. Hybrid semi-finished components are produced by applying a high-alloy cladding to a low-alloy base material before hot-forming and machining the workpiece. Throughout this process chain, workpiece deviations in the form of material distribution and material properties can occur that influence the component’s lifetime. This paper investigates whether such workpiece deviations can be detected within the process chain by analyzing process signals obtained from subsequent process steps. For this purpose, artificial workpiece deviations were introduced to hybrid semi-finished workpieces made of C22.8/X45CrSi9-3. Then, process signals during forming and machining were analyzed to determine their sensitivity to the artificial deviations. The results revealed that deviations in cladding size can be effectively monitored using signals from both forming and machining. Cladding position deviations can only be detected during machining, while forming signals are more responsive to detecting the introduced hardness deviations of approx. 100 HV0.1.
Organisation(s): Institute of Production Engineering and Machine Tools
Institute of Metal Forming and Metal Forming Machines
Institute of Transport and Automation Technology
External Organisation(s): Institut für integrierte Produktion Hannover (IPH)
Laser Zentrum Hannover e.V. (LZH)
Type: Article
Journal: International Journal of Advanced Manufacturing Technology
Volume: 130
Pages: 2649-2659
No. of pages: 11
ISSN: 0268-3768
Publication date: 01.2024
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Control and Systems Engineering, Software, Mechanical Engineering, Computer Science Applications, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.1007/s00170-023-12807-x (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{a5ea5d959a6a41b5aaab4668558efd93,
title = "Sensitivity of process signals to deviations in material distribution and material properties of hybrid workpieces",
abstract = "Hybrid components, made of multiple materials, can meet the increasing demands for lightweight construction and functional integration in the automotive and aircraft industry. Hybrid semi-finished components are produced by applying a high-alloy cladding to a low-alloy base material before hot-forming and machining the workpiece. Throughout this process chain, workpiece deviations in the form of material distribution and material properties can occur that influence the component{\textquoteright}s lifetime. This paper investigates whether such workpiece deviations can be detected within the process chain by analyzing process signals obtained from subsequent process steps. For this purpose, artificial workpiece deviations were introduced to hybrid semi-finished workpieces made of C22.8/X45CrSi9-3. Then, process signals during forming and machining were analyzed to determine their sensitivity to the artificial deviations. The results revealed that deviations in cladding size can be effectively monitored using signals from both forming and machining. Cladding position deviations can only be detected during machining, while forming signals are more responsive to detecting the introduced hardness deviations of approx. 100 HV0.1.",
keywords = "Cross-wedge rolling, Laser hot-wire cladding, Machining, Monitoring, Workpiece deviations",
author = "Berend Denkena and Behrens, {Bernd Arno} and Ludger Overmeyer and Stefan Kaierle and Benjamin Bergmann and Heinrich Klemme and J{\"o}rg Hermsdorf and Malte Stonis and Nick Schwarz and Laura Budde and Paulina Merkel and Miriam Handrup",
note = "Funding Information: Open Access funding enabled and organized by Projekt DEAL. This research was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) - CRC 1153, subprojects A04, B01, B05 - 252662854. ",
year = "2024",
month = jan,
doi = "10.1007/s00170-023-12807-x",
language = "English",
volume = "130",
pages = "2649--2659",
journal = "International Journal of Advanced Manufacturing Technology",
issn = "0268-3768",
publisher = "Springer London",
number = "5-6",
}