Institute of Production Engineering and Machine Tools Research Current projects
SFB 1153 - B4: Function-adapted process planning for the machining of hybrid components

SFB 1153 - B4: Function-adapted process planning for the machining of hybrid components

Year:  2017
Date:  20-12-17
Funding:  DFG
Duration:  07/2019 - 06/2023
Further information

The machining has, as a final step in the process chain of solid components production over the manufactured surface and subsurface properties, a significant influence on the application behaviour and the life span of components. A possibility to use this knowledge already in the design phase of the component to define a machining strategy does not exist yet. Hence, the aim of the subproject B4 is to connect the design of a component with its process planning. Thus the effects of function-specific surface and subsurface properties like topography or residual stress gradient on the application behavior can be considered already in the design phase and transferred via an integrated process planning into the manufacturing process. As a result of this project, the design engineer will be able to include function-specific aspects like tribological properties or optimized residual stress courses in the component design.


In the first period, the basic correlations of the surface and subsurface influences by the machining process will be examined in example materials for a function oriented process planning. A special challenge will be the analysis of the subsurface properties in the area of the material transition in hybrid components. Hence, a combination of experimental and simulation-based work is necessary. The underlying effects of chip formation and surface development as well as the resulting structure influences and residual stress formation will be first examined in the single materials and afterwards be transferred to hybrid components. The energy dispersive X-ray diffraction will be qualified and used for the quantification of the residual stress courses in the component subsurface as well as their load-influenced changes (Figure 2).

Fatigue tests as well as rolling fatigue strength investigations in cooperation with the subproject C3 allow the identification of the life-determining surface and subsurface properties. The parallel transfer of knowledge between simulation level and reality forms the basis for the computer-supported planning of function-adapted processes for the machining. The simulation of the complex thermo-mechanical interaction in subproject C4 presents an important aspect of the cooperation. The material characterization which will be carried out together with the subprojects A1 and A2 form the basis of a cross-process understanding of the component properties resulting from the production. For a successful completion of the project the interdisciplinary cooperation with the other subprojects of the CRC is of essential meaning.