No abstract

Numerical solutions of manufacturing process chains strongly focus on supporting the production of frame structures in the vehicle industry. Frame structures play a central role in all means of transportation, dominating the total mass in automobiles, trains, airplanes, and even space ships. In the case of automobiles, the frame structure mass constitutes about 30% of the total mass. In the case of the automotive industry, the mass-production, the high-quality standards and the need for mass minimization all increase the necessity to apply virtual manufacturing methods in the production cycle of frame structures. In scope of this paper, a method of chaining the numerical analysis of the structural effect on frame components during successive manufacturing processes is introduced. The change of thermal, metallurgical, and mechanical properties in structures during manufacturing is analyzed by applying theoretical models depending on the identified problem.

The innovative production methods Composite Extrusion and Friction Stir Welding are used to manufacture lightweight frame structures made of steel reinforced aluminium. In order to optimise the processes themselves and the manufacturing of frame structures both processes are analysed in a structural simulation. One result of these simulations is the distribution of the residual stresses in the reinforced profiles. The simulation results are compared with measurements of the residual stresses by means of neutron scattering.

Generally, the manufacturing of lightweight frame structures involves various processes that yield the final product. Simulation methods can be used to optimise the different process steps. When chaining these process steps together in the simulation, software interfaces become necessary to realise an integrated virtual process chain. In this paper two approaches are presented that solve this issue and demonstrate it for an exemplary part. Different software tools with appropriate interfaces and the use of only one software tool for the simulation of the whole process chain are investigated respectively. The results of both approaches are analysed and relevant conclusions are deduced.

Kurzfassung Die zunehmenden Anforderungen an die Fertigungsgenauigkeit von Produktionsanlagen konfrontieren Wirtschaft und Wissenschaft mit der anspruchsvollen Aufgabe, nicht nur den Prozess an sich, sondern auch die Interaktion mit dem Bauteil sowie dessen Reaktionen zu beherrschen. Insbesondere bei den Schmelzschweißverfahren sind die strukturmechanischen Auswirkungen enorm und beeinflussen dementsprechend maßlich das Ergebnis. Am Beispiel des Laserstrahlschweißens soll gezeigt werden, wie sich mittels einer Kombination von computerbasierten Methoden die Verzugsausprägung effizient berechnen und reduzieren lässt.