Modelling, simulation and digitisation

Artificial intelligence is becoming established in many areas of life. The large number of sensors and data that can be integrated or recorded in the manufacturing process provides an ideal basis for using artificial intelligence in manufacturing technology. This means that process changes can be detected very quickly on the basis of the data and necessary measures can be derived. In addition to extensive data, suitable models must also be selected and trained.

The structural welding simulation is used at the Production Technology Group as a process-accompanying tool for the clarification of technical welding questions such as microstructural transformationsresidual stresses or component distortion.. The welding simulation on the numerical solution of a model and is validated by comparison with experimental tests. The comparison of different process variations, materials or clamping conditions makes it possible to an optimized approach for the selected welding task. Weld structure simulation is used in addition to additive manufacturing welding, it is also used in joint and buildup welding.

The SPH method is a modern approach to the simulation of liquid or gas flows and also enables the determination of solid deformations, which occur, for example, during friction stir welding. The work of the Production Technology Group deals with the modeling of the tool and the materials in order to obtain statements on the mixing of materials by the tool or on the wear of the tool.

One area of structural optimization is topology optimization. Numerical calculation methods are used to generate design proposals for stresses and evaluate them in terms of utilization. This allows material-reduced and load-compatible structures to be determined. For implementation by the DED-arc additive manufacturing process, process-specific boundary conditions must be taken into account when performing topology optimization.

Distortions occur in every manufacturing process, which can strongly influence the use of the joint and structure. Non-destructive detection and rapid evaluation of the distortion enable a description of the deviations from target and further analyses can be used to derive adjustments to the process parameters.