Multi-layer compounds with integrated actor-sensor-functionality

Abstract

A method is presented to integrate the cost and time consuming afterwards-joining technologies of piezo actors and sensors direct in the forming processes for metal blank structures. Possible applications for such parts are vibration/ noise damping, deformable shape control, energy harvesting or several sensor tasks. Different forming processes are experimentally investigated and the limits according to deformation of the brittle piezo components discussed. In the numerical research the piezomodule components (piezo fibre, electrodes and plastics embeddings) are homogenized to create a computation-time reducing simplified material model. In a back-transfer of global loads in the forming simulation a representative volume element (RVE) with cyclic boundary conditions is used to evaluate the loading of the piezoceramic material to describe the function degradation due to forming operation. The comparison of numerically and experimentally determined results in a linear manner lead to the necessarity of further numerical research. The location of maximum piezo-patch loading corresponds well with the numerical investigation. The numerical integral model for function degradation shows a large difference in comparison to the integral experimentally determined values. Therefore extensive experimental research direct on the piezomodule outside the forming compound is planned to fit the degradation model in a nonlinear manner

Modelling and simulation of adhesive curing processes in bonded piezo metal composites

“…After the forming process, the adhesive cures to a solid and thereby provides a material closure between the MFC and the light metal structure in the formed state. The principal feasibility of this method could already be demonstrated in earlier studies (see, for instance, [5,31,32]).…”

“…Finally, it is intended to employ the presented approach to the simulation of different deep drawing processes (cf. [31,32]). loaded in hydrostatic tension (p < 0), the condition (97) may be violated.…”

“…Despite excellent properties of piezoceramic patches, the state of art is their application to the fabricated parts only after manufacturing which leads to a time and cost intense procedure [31]. Scientific fundamentals for an economic production of active structural components are worked out in the Collaborative Research Center/Transregio "PT-PIESA".…”

Materials in machine tool structures

“…Piezo integrated composite structures were developed in Ref. [174,203]. Drossel et al investigated the integration of piezoceramic fibers into aluminum sheets by forming processes [74,75] (Fig.…”

Active Vibration Damping in Structural Aluminum Die Castings via Piezoelectricity – Technology and Characterization

“…Two main approaches for embedding piezoelectric elements into aluminum structures can be found in recent studies: via forming and casting. Production technologies to manufacture sheet sandwich structures with integrated MFCs (macro fiber composites – M 8528‐P1, distributor: Smart Materials GmbH, Dresden, Germany) have been developed by Neugebauer et al A different approach with aluminum sheets is followed up by Schubert et al A direct integration is implemented by micro‐forming processing. DLC or SiCN:H coatings are applied to previously created micro‐cavities.…”