Roeren, S.; Schikorra, M.; Kersting, M.; Stautner, M.:
In: AMPT-Conference 2006, Advances in Materials and Processing Technology, 2006


Within the Transregional Research Center `Transregio 10´, funded by the German Research Society DFG, approaches and methods are developed for the economic production of lightweight structures. With regard to low production batches, simulation enables early predictions for dimensioning and optimization of both manufacturing processes and product design. Along a chain of the processes extruding, milling, drilling, and welding the structural behavior of a treated hollow aluminum-profile is investigated. The Finite Element Analysis (FEA) is used to calculate physical effects of these processes during and immediately after treatment. Especially, the milling process is simulated by a custom cutting simulation, which is able to evaluate engagement conditions. A special aspect of the collaboration is the integration of single process steps into a simulated process chain. Therefore, the results of a previous calculated process are defined as the initial condition of the following simulation step. The importance of defining a process chain by simulation becomes apparent when contemplating the results. The integration of physical values resulting from previous steps, e. g. temperature or residual stresses, leads to a different structural behavior compared to a mere geometry-model as input data for the succeeding simulation. An approach for the implementation of data and the investigation of their physical effects is presented. Furthermore, the prospect of an advanced strategy for model-management is given. Hereby, a master-model is defined that provides information and a specific set of data needed for each single process. After calculation of one manufacturing process, the results are written again into the master-model. Thus, both consistency in a physical context and flexibility in analyzing process-chains can be realized.