In-process calibration of smart structures produced by incremental forming
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PRODUCTION PROCESS
In‑process calibration of smart structures produced by incremental forming Nassr Al‑Baradoni1 · Martin Krech1 · Peter Groche1 Received: 23 July 2020 / Accepted: 11 November 2020 © The Author(s) 2020
Abstract Smart load-bearing structures are created by forming integration of functional materials into passive metallic components with target-oriented pre-stress conditions by rotary swaging. Their sensory capability cannot only be used during the utilization but also during the manufacturing phase. Previous works demonstrated how this capability paves the way for efficient monitoring and controlling of the used integration process. In search of an even higher overall efficiency of the manufacturing chain, the subsequent costly calibration step deserves closer attention. Therefore, a cost- and time-efficient approach for the process-integrated calibration of a sensor-integrated structure is proposed in this paper. During the in-process calibration, the acting process forces are measured both in the integrated sensor and in a special-built clamping fixture. The measured data can be transferred into calibration slopes of the sensory structures. A suitable signal processing based on the process characteristics is performed to compensate interference effects on the raw signals. As a result, an accuracy of the calibration better than 2% of the nominal value compared to an offline standardized calibration is achieved with the in-line calibration method. Consequently, efficiency in the manufacturing of sensory structures is further boosted by avoidance of setup or logistical operations. Keywords Smart structures · Calibration of smart structures · Incremental forming · Joining by forming
1 Motivation Today, load-bearing structures usually fulfill a purely mechanical function: transmit forces and torques safely to ensure reliable and trouble-free operation. To satisfy this requirement, these structures are traditionally dimensioned conservatively taking into account safety factors. However, this approach is expensive and an obstacle to lightweight designs. Within the scope of digitization, the demand for additional sensory or adaptive functions at low cost and high robustness is emerging. In order to meet this demand, many researchers are investigating a multitude of manufacturing technologies for multifunctional metallic structures with integrated functional materials. In general, research in the production of smart structures using composite materials and hybrid structures is widely driven forward. For instance, the production of * Nassr Al‑Baradoni al‑[email protected]‑darmstadt.de 1
Technical University Darmstadt, Institute for Production Engineering and Forming Machines, Darmstadt, Germany
polymer-based piezoelectric applications by additive manufacturing [1] or the integration of a piezo module by forming the initially powdery structural material layer by layer through a selective laser sintering process [2] have gained interest. The combination of a highly enriched thermoplastic polymer with
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