Papers by Author: Michael F. Zaeh

Abstract: In view of the demand for electrified long-range vehicles, the performance of traction batteries has to be improved. To achieve a high power density, the battery cells must be interconnected with low electrical resistance within the joints. The joining process has to fulfill specific requirements, as the battery cells may only be exposed to very low mechanical and thermal impacts. Joining by using reactive aluminum-nickel nanofoils represents an innovative technology meeting the abovementioned requirements. These foils are multilayered systems consisting of several hundred alternating monolayers of aluminum and nickel, each with a thickness in the nanometer range. Their unique ability is that they can react with temperatures up to 1500 °C for a duration of a few milliseconds upon external ignition. This thermal reaction energy serves as a heat source in the joining process, melting the materials in the interfacial surface. Subsequently, the joining partners solidify and form an adhesive bond when compressed properly. However, these advantageous characteristics are contrasted by complex reaction mechanisms and an unknown interaction of the process parameters. For the industrial application of the joining technology, the requirements for initiating the exothermic reaction must be known. Therefore, the process window and the mechanism of ignition have to be scrutinized. For this purpose, an experimental test setup was developed to generate and monitor short circuit currents to ignite the nanofoils. The amperage as well as the layer composition of the nanofoils were varied within a parameter study. Two independent process windows for a stable ignition were identified for all analyzed nanofoils.

Abstract: The electric base load of milling machine tools has a high share of the machine’s total energy consumption. An approach to decrease the energy demand per workpiece is to shorten the machining time by raising the material removal rate. The maximum feed depends on the tool’s wear resistance while the maximum depth of cut is often limited by the chatter stability of the machine. In this paper active damping is used to damp chatter vibrations, which leads to a higher depth of cut. To evaluate the decrease of energy consumption for any workpiece, a modeling methodology for the energy demand of machine tools was developed, which is presented in this paper. The methodology is able to estimate the energy requirements of the spindle during cutting, of the feed drives, of the auxiliary equipment and of the base load. The numerical results were experimentally validated by different 2.5D machining processes, with good agreement between the simulation model and the experimental results. Therefore, the proposed methodology can be used effectively for calculating the total energy required for the machining of any workpiece. In addition, the structural dynamics of the machine tool, the active damping system and the cutting process were modeled in order to simulate the chatter stability. This enables a straightforward determination of the optimum cutting parameters as well as a comparison of different milling part programs, both in terms of the energy demand. Furthermore, it is possible to evaluate the energy conservation by active damping and to point out for which cutting processes active damping is useful.

Abstract: Besides the energy efficiency approach to reduce energy demands of production systems there are also other possibilities to decrease the energy related operating costs. Amongst others avoiding long-term peak loads represents a common measure. In possible future cases a flexible energy demand of factories can also be refunded by the energy provider within new tariff structures. This paper shows the potentials of production systems to alternate their energy demand within productive state, which is also referred to as technical energy flexibility. The focus is on machines of sensitive main processes, where an influence on the energy demand could induce distinct negative effects on the product quality. It is shown how and to which extent the energy demand of production systems can be controlled without negative effects.

Abstract: In order to support production tasks in the automotive industry, to reduce costs due to a trial and error procedure during process design and plant construction and to secure the accuracy of frame component assemblies, modern simulation methods are applied. In production chains a row of different manufacturing techniques are established. To accompany the number of manufacturing steps with the aid of calculation methods, an interacting of each simulation with the preliminary one is necessary. Such process chains help to determine the structural properties and geometrical accuracy of components and assemblies during manufacturing of composite lightweight structures and ensure their final quality. The basic difficulty of handling aluminium composites with steel reinforcements is the high residual stress level in the reinforcing elements and the adjoining matrix. This stress state can have a significant effect on the desired machining results and the related process itself. Contemplating this reveals the importance of defining a process chain by simulation.

Abstract: In the field of light weight frame structures the assurance of dimensional accuracy and the prediction of structural properties especially during and after welding processes are of great importance. The problem in this regard mostly arises from the used welding technique which is characterised by complex interactions of various parameters. A simulative approach is useful in order to predict the structural behaviour and to improve the geometrical quality of joined light weight components after welding. As such, it contributes to reduce process adjustments in the early stage of the product life cycle, and therefore helps to save time and costs. In this paper an approach for modelling the innovative joining process of composite extruded profiles by friction stir welding is presented.

Abstract: On a global market, new products are subject to rising requirements regarding strength and quality. Simultaneously, the conservation of the environment and natural resources has become a key priority. One approach to these demands is the weight reduction of mechanical components by lightweight construction. The Transregional Collaborative Research Center (TR 10), funded by the German Research Foundation (DFG), is therefore working on the “Integration of forming, cutting and joining for the flexible production of lightweight space structures”. The use of light metals, like aluminium and composite materials is a main part in the TR10 process chain. This paper deals with the challenges of welding of light weight components made out of EN AW-6060. It shows the use and potentials of two innovative joining processes, particularly suited for welding aluminium. Especially developed for the fusion welding of aluminium components, BHLW (Bifocal Hybrid Laser Beam Welding), combines a Nd:YAG and a high power diode laser. The paper will give insight into the findings of the achieved results so far and line out the further proceedings with regard to critical parameters and their effect on the overall laser welding process. For the welding of aluminium composite materials, which play a big role in the TR10 process chain, Friction Stir Welding (FSW) is evaluated. As a solid state joining process, it can be used for the welding of materials that are hardly weldable with fusion welding techniques. In this paper, results of basic experiment for the joining of reinforced aluminium and the resulting process forces are presented.