A numerical and experimental analysis of a rotary swaging process for manufacturing smart structuresThursday (29.09.2016) 10:00 - 10:15 Part of:
This presentation deals with a novel rotary swaging process for manufacturing thin-walled tubular parts with integrated functional elements. The economic integration of piezo ceramic materials and strain-gauge based elements into hollow tubular machine elements enables a wide-spread use of smart structures. The tight coupling of the functional element inside the work piece gives the possibility for load and condition monitoring as well as active applications. The forming process is adjusted in order to guarantee a damage-free integration of the fragile functional elements and to maintain the full mechanical functionality of the part. By a local wall thickening undercuts inside the tube are generated, whereas the outer surface maintains a smooth contour. An effective utilization of the function-integrated part requires the elements to lie in the force flow path which is enabled by a mechanical pretension. In order to set up the targeted pretensions, the integrated sensory elements itself are used to measure the pretension forces during forming. Additionally, a fully coupled thermo-mechanical 3D-Finite Element Model is used to analyze the underlying joining mechanisms. The two basic process principles of rotary swaging, infeed and recess swaging are compared to each other regarding their suitability for joining and pretensioning functional elements. With the help of the numerical model, important influencing factors are pointed out and process design guidelines are derived. Finally the sensory and actuatory functionality is tested and the importance of the pretension is pointed out.