Extrusion of screws with sensor functionality

Abstract

The use of components with embedded sensors is one of the most promising trends in civil engineering, plant construction and mechanical engineering. These components make it possible to both monitor the design state in real time and to recognize failures in parts and components early on. However, due to high product costs, their wider distribution is limited. Optimization of the component manufacturing technology can contribute to reducing the production costs.Fasteners, such as screws and rivets, consisting of a polypropylene composite core filled with piezoceramic powder represent a potential approach. In the event of a sudden impact, this compound generates an electric pulse, and through machine learning the cause of the failure can be filtered out from the screw’s normal state.Simultaneous forming of aluminum and plastics opens up new opportunities to produce the abovementioned screws at a reasonable price. The authors’ aim was to demonstrate feasibility through initial experiments and the generation of a simulation model.