In the Addi-Randschicht project, we are investigating how an additive-subtractive process chain influences the fatigue life of aluminium components. The aim of your thesis is to develop a 3D finite element simulation model of the deep rolling process. The model is intended to describe the influence of local inhomogeneities on the resulting surface and subsurface properties and thus form the basis for predicting fatigue life.

You will support us with:

• Development, implementation, and evaluation of the simulation
• Transfer of the simulation model to inhomogeneous, additively manufactured materials
• Validation of the simulation using experimentally determined subsurface properties
• Derivation and interpretation of relevant quantities for fatigue life prediction

Ideally you have:

• Interest in production technologyand numerical simulation

• Basic knowledge of structural 3D FE simulation using ANSYS, ABAQUS, or a comparable simulation software

Within a research project on the simulation-based design of coated cutting tools, an FE-based wear model is to be developed. The objective is to describe continuous tool wear in the turning process considering thermomechanical loads and to implement the model into an existing chip formation simulation framework.

You will support us with:

• Literature research on wear models in machining
• Development of an FE-coupled wear model
• Implementation of the model into an existing FE simulation
• Execution and evaluation of selected test simulations

Ideally you have:

• Interest in machining processes and FEM
• Structured and independent working style

In the reFrame project, we are investigating energy-efficient layup strategies in thermoplastic Automated Fibre Placement (TAFP) at the CFK Nord research centre in Stade. To this end, we are analysing the energy consumption of individual machine components while varying key process parameters. The results of your work will thus contribute to reducing energy consumption and CO₂ emissions in automated composite manufacturing.

You will support us with:

• Selecting and implementing suitable energy measurement systems
• Preparing, carrying out and evaluating energy measurements during the TAFP process
• Modelling energy consumption as a function of process variables
• Identifying and investigating optimisation potential for increasing energy efficiency

Ideally you have:

• Basic knowledge of automation or manufacturing technology
• Programming skills (for example, MATLAB or Python)
• High motivation and independent way of working

The nature and scope of the work can be determined individually. Experimental work is to be carried out in Stade, while analysis, evaluation and modelling can be done from any location.

During tool grinding (e.g. of milling and drilling tools), the design of the grinding process plays a central role. Especially in flute grinding, high thermomechanical loads occur, which vary significantly due to wear on the grinding wheel surface. To better understand these processes, grain-resolved simulations are used that capture the material removal of individual abrasive grains. For this, realistic grinding wheel surfaces must be digitally reconstructed. In your work, you will further develop an existing model for diamond grinding wheels together with us, making use of results from experimental grinding tests.

You will support us with:

• Extensive literature review
• Planning and execution of grinding tests
• Measurement and evaluation of surface scans
• Development and implementation of algorithms in existing simulation software (C# / .NET Framework)

Ideally you have: 

• Interest in manufacturing technology
• Experience in working with machine tools / grinding machines
• Very good programming skills in C# / .NET Framework

During tool grinding (e.g. of milling and drilling tools), the design of the grinding process plays a central role. Especially during flute grinding, high thermomechanical loads occur due to high material removal rates. To better understand the influence of different coolant strategies and process parameters, grinding experiments are carried out. In your work, you will investigate the effect of coolant strategies and evaluate the experimental data with regard to temperatures inside the workpiece as well as the resulting grinding forces. The data will then be used for the parameterisation and validation of grinding process models and simulations.

You will support us with:

• Extensive literature review
• Planning and execution of grinding tests
• Measurement and evaluation of process forces, temperatures, and topographies
• Analysis and modeling of thermomechanical load

Ideally you have: 

• Interest in manufacturing technology
• Experience in working with machine tools/grinding machines
• Programming skills in Matlab

How does the environment influence the machining process? You will investigate this question in your thesis. When machining titanium, unfavourable chip formation occurs at high temperatures. One reason for this is the presence of oxygen in the air. Using an oxygen-free machining atmosphere reduces thermo-mechanical stress and tool wear, while also improving chip formation. However, the interactions involved have not yet been investigated.

You will support us in:

• Creating high-speed recordings of the titanium machining process
• Process-parallel analysis of the interactions between atmosphere, chip formation and tool wear
• Optimisation of the process technology we have developed

Ideally you have:

• An affinity for high-speed camera technology
• An interest in machining technologies