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Professorship for Adaptronics and Lightweight Design in Production
Research projects

Research projects

 

 

 

 

SimiKom - System integration of miniaturized components for structure-integrated, wireless sensor technology in mechanical engineering

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  • Partner: Fraunhofer (IPMS, ENAS, IIS, IZM - ASSID), TU Dresden, HTW Dresden
  • Main objective: The aim of the research project integrated into the performance center "Function Integration for Micro-/Nanoelectronics" is to extend previous research work on the integration of sensors using the example of a ball screw drive to realize both information and energy transfer and to enable the system to react to measured quantities by integrating suitable actuators.
  • Contact:
    Amir Nemati, M.Sc.
  • Project duration: 10/05/2019 – 31/12/2020
  • Funded by: This measure is co-financed with tax revenues on the basis of the budget adopted by the Saxon State Parliament.
  • Further information at the website of the performance center.

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Development of a control model for predictive control data to expand the process limits of piezo kinematic systems for production technology

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  • Main objective: Objective is, to realize a "predictive" calculation of the required control signals to use piezo systems above the controller bandwidth. Up to now, the drive signal has been iteratively adapted from production step to production step until the deviations of the production result lies within a defined tolerance range to the target specification.
  • Contact:
    Roman Baraniuk, Ph.D.
  • Project duration: 01/03/2019 – 28/02/2021
  • Funded by: Deutsche Forschungsgemeinschaft (DFG)

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Since the piezo kinematics have a very good repeat accuracy, an iterative process has therefore been developed in further investigations. From control engineering, the method of "iterative learning control" (ILC) can be used to describe the general procedure. With the ILC, for periodic signals, after the passage of a period, the drive signal is corrected by the existing error. For the subsequent iterative production process carried out, the period would therefore amount to several hours and be carried out "manually". It is relevant to create such model with the help of which it would be possible to predict the dynamics of a given system, thereby getting rid of this iterative process. Having must-shape X and using the model, the input signal can be found, applying which Y=X output will be received given the fluctuations and dynamics errors.


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UltraSMAwire – Effect stabilization of thermal shape memory alloys by vibration assisted wire drawing

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  • Partner: Ingpuls GmbH, DEVAD GmbH, Kieselstein International GmbH
  • Main objective: Improvement of the material properties of SMA wires and of their manufacturing process through ultrasonic assistance
  • Contact:
    Jonas Maximilian Werner, M.Sc.
  • Project duration:01/11/18 – 30/10/2020
  • Funded by: Bundesministerium für Bildung und Forschung

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To meet the specifications of NiTi wires for a technical application, the generation of a specific microstructure is necessary. Additionally, a higher efficiency of the manufacturing process by eliminating process steps, possible through higher deformations, is possible, thereby achieving a higher market acceptance.

The aim of the project is to improve the fatigue strength of shape memory alloy wires. Through ultrasonic assistance, the necessary force for drawing of the wire can be reduced by 40%, causing a lower risk of tearing and enabling higher deformations. Furthermore, ultrasonic assistance enables the generation of a fine-grained microstructure. Because of this, an improvement of the shape memory effect is to be expected.


 

 

Crack location and crack width determination on concrete structures by means of shape memory alloy-based fibers

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  • Partner: Marx Krontal GmbH, Ingpuls GmbH, TU Dresden, Hentschke Bau GmbH
  • Main objective: Development of sensor systems for robust, permanent crack detection in concrete structures based on shape memory alloy sensors.
  • Contact:
    Dipl.-Ing. Inaki Navarro y de Sosa
  • Project duration: 01/11/2018 – 30/04/2021
  • Funded by: Bundesministerium für Bildung und Forschung, Förderprogramm „Zwanzig20 - Partnerschaft für Innovation“

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Cracks can lead to damage and failure of concrete structures such as bridges, dams or tunnels. If cracks are detected too late, high costs for repair or demolition and new construction of damaged concrete structures are incurred. Condition monitoring and location of cracks in concrete volume is very complex and cost-intensive. In addition, currently there is no robust and permanent method for continuous early crack detection, localization and width measurement available on the market.

The aim of the project is, to develop a method and technology for a robust and permanent crack detection in concrete structures, which at the same time enables crack location and crack width determination. Nickel-titanium thermal shape memory alloys are to be used as sensor material.


 

AMARETO – Saxon Alliance for MAterial- and Resource-Efficient TechnOlogies

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  • Partner: TU Chemnitz, TU Dresden, TU Bergakademie Freiberg, Fraunhofer IWU, Industry
  • Main objective: Focusing of competences across Saxon locations in the areas of Smart Materials, Smart Design, Smart Production
  • Contact:
    Jonas Böttger, M.Sc.
  • Project duration: 01/01/2017 – 30/06/2020
  • Funded by: European Union and the Free State of Saxony at the hands of Development Bank of Saxony (SAB)

Process-related failure in hard finishing processes and its influence on acoustic conspicuousness of gearwheels is one topic of research at our professorship. Requirements regarding quietness of gears have been increasing in recent years. This is especially motivated by electric mobility and, coupled with that the absent acoustic masking of a combustion engine. Unfortunately, process-related deviations and their influence on acoustic emissions have not yet been sufficiently explored to identify them in widespread finishing processes like gear grinding. The objective is to detect these deviations in real-time and to intervene in the process accordingly. Furthermore, possibilities to apply actuators close to the tool to assure workpiece quality shall be examined.

Further information at: http://amareto.info


 

 

Modelling and design of systems for active control of temperature distribution in frame subassemblies

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  • Partner: TU Dresden, RWTH Aachen, Fraunhofer IWU, Fraunhofer IPT
  • Main objective: Within CFC/Transregio 96 novel approaches to compensate thermal errors in machine tools are investigated. Sub-project C02 aims for the integration of latent heat storages in machine tools in order to achieve improved thermomechanical machine behavior. By using phase change materials, temperature fluctuations can be reduced.
  • Contact:
    Immanuel Voigt, M.Sc.
  • Project duration: 01/07/2011 – 30/06/2019
  • Funded by: Deutsche Forschungsgemeinschaft (DFG)
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Latent heat storages exhibit high energy density within the phase-change temperature range. Due to their high transition enthalpies, occurring heat flows can be controlled in order to counter undesirable temperature variations of the machine structure.

Selected publications:

  • Drossel, W.-G.; Voigt, I. Wärmespeicher in Werkzeugmaschinen. VDI-Z Integrierte Produktion 158. 2016.
  • Ohsenbrügge, C.; Marth, W.; Navarro y de Sosa, I.; Drossel, W.-G.; Voigt, A. Reduced material model for closed cell metal foam infiltrated with phase change material based on high resolution numerical studies. Applied Thermal Engineering 94. 2015.
  • Neugebauer, R.; Drossel, W.-G.; Bucht, A.; Ohsenbrügge, C. Control of thermal flow in machine tools using shape memory alloys. World Academy of Science, Engineering and Technology 71. 2012.

Further information at: http://141.30.75.25/SFBweb/


 

 

ReBoneS - development of realistic bone models with integrated sensors

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  • Partner: Fraunhofer IWU (Department Medical Engineering, Department of Applied Plastics Technologies), Professorship Machine Tools and Forming Technology
  • Main objective: development of artificial, biomechanically correct bone models
  • Contact:
    Constanze Neupetsch, M.Eng.
  • Funded by: Initiative Biotechnologie und Lebenswissenschaften - Sächsische Staatsministerium für Wissenschaft und Kunst (SMWK)
  • Project duration: 01/04/2018 – 31/12/2020

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The aim of the project is the development of artificial, biomechanically correct bone models, e.g. for implant testing. In addition, sensors for the detection of load conditions are integrated into these. The results may be used to simplify and standardize biomechanical testing in the future. Furthermore, the new bone models objective is to reduce the time-consuming and expensive tests on human samples.


 

 

Highly dynamic linear actuators based on magnetic shape memory alloys

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  • Main objective: Development of own actuator design concepts based on magnetic shape memory alloys, which allow higher dynamics and thus new fields of application. Shortcomings of previous actuators regarding their application in the dynamic range are evident from the state of research. By means of an innovative cross-domain design methodology, these boundaries have to be overcome and novel actuator designs for the medium frequency range have to be developed.
  • Contact:
    Christian Titsch, M.Sc.

 

 

System analysis and design of piezoelectric ultrasonic systems for production engineering

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  • Main objective: Design methodology to describe ultrasonic systems as an adaptronic system, to capture the complex interaction of electrical, mechanical and thermal parameters.
  • Contact:
    Christian Titsch, M.Sc.
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Ultrasonic assited processing is often used in production enginnering, for example to reduce tool wear or processing forces. The positive effects are not consequent detectable. The cause-and-effect relationships of different effects for example the take-off effect, application of energy and the adiabatic effect are not experimental approved. Also a design methodology to describe ultrasonic systems as an adaptronic system, to capture the complex interaction of electrical, mechanical and thermal parameters is not available. Multiphysical simulations as well as experimental studies are research areas of the Professorship for Adaptronics and Lightweight Design in Production.

Publications:

  • Titsch, C.; Müller, M.; Drossel, W.-G.: Experimental investigation of the infuence of external forces on ultrasonic parameters for ultrasonic-assisted turning. In: Proceedings of the 6th International Conference on Competitive Manufacturing (COMA ’16), 2016, S. 321-326

 

 

Switchable heat transfer

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  • Main objective: Realization of switchable heat transfer to enable effective and demand-actuated temperature control.
  • Contact:
    Immanuel Voigt, M.Sc.
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Switchable heat transfers are in a wide field of applications promising tools to control temperature distribution. At the propfessorship investigations concerning the application of thermal shape moemory alloys (SMA) as well as magnetorheologic fluids have been realized. A remarkable feature of a thermal switch based on SMA is the capability to operate stand-alone without external power supply or control.

Publications:

  • Schneider, Dorothea ; Lauer, Martin ; Voigt, Immanuel ; Drossel, Welf-Guntram: Development and examination of switchable heat pipes. In: Applied thermal engineering Vol. 99 (2016), S.857-865 (DOI: http://dx.doi.org/10.1016/j.applthermaleng.2016.01.086.)
  • Neugebauer, Reimund ; Drossel, Welf-Guntram ; Bucht, André ; Ohsenbrügge, Christoph: Control of thermal flow in machine tools using shape memory alloys. In: World Academy of Science, Engineering and Technology, WASET. Proceedings (2012), Nr.71, S.697-701 (URL: http://waset.org/publications/3230/control-of-thermal-flow-in-machine-tools-using-shape-memory-alloys)
  • Drossel, Welf-Guntram ; Bucht, André ; Ohsenbrügge, Christoph: Thermische Leitfähigkeit magnetorheologischer Fluide. In: TU Dresden, Institut für Werkzeugmaschinen und Steuerungstechnik: Thermo-Energetische Gestaltung - eine systemische Lösung des Zielkonflikts von Energieeinsatz, Genauigkeit und Produktivität am Beispiel der spanenden Fertigung. (URL: http://publica.fraunhofer.de/documents/N-266821.html)

 

 

Impact of production process on vibration excitation in gears

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  • Main Objective: Quantification of the impact of possibly error-prone production processes on tooth flank topography and resulting acoustic properties by simulation of finishing process.
  • Contact:
    Dipl.-Ing. Simon Kimme
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The acoustic properties of automotive gearboxes get more and more crucial in the context of decreasing masking noise of the engine. Especially the gear mesh as a main noise source is of interest. At the professorship a simulation model for continuous generating grinding, a commonly used finishing process is developed. It enables investigations on various deviations in the grinding process. By discretization of tool, work piece and process information on process values as well as resulting flank topographies can be gained. This helps to solve issues in the production process targeted and enables an early detection of deviations in the grinding machine. New methods for analysis of noise-relevant structures on the tooth flank allow evaluation of simulated as well as measured flank topographies.

Publications:

  • Kimme, Simon; Drossel, Welf-Guntram; Decker, Harald; Lührs, Georg-Friedrich: Auswirkung von Maschinenschwingungen auf die Zahnradherstellung: Vortrag gehalten bei der VDI-Konferenz Schwingungen in Werkzeug- und Verarbeitungsmaschinen; 10. und 11. Mai 2016, Darmstadt. 2016, 25 Folien (URL:http://publica.fraunhofer.de/documents/N-393584.html.
    Erstelldatum: 18.5.2016. Zugriffsdatum: 20.2.2017)
  • Kimme, Simon; Bauer, Ruben; Drossel, Welf-Guntram; Putz, Matthias: Impact of gear finishing processes on micro geometry - simulation of defective production processes and resulting acoustic properties. In: VDI-Wissensforum GmbH: 6th International Conference on Gears 2015: October 5th to 7th, 2015, Garching, Munich Düsseldorf: VDI-Verlag, 2015, S.227-238 (VDI-Berichte 2255)
  • Kimme, Simon; Bauer, Ruben; Drossel, Welf-Guntram; Putz, Matthias: Simulation of error-prone continuous generating production processes of helical gears and the influence on the vibration excitation in gear mesh. In: Procedia CIRP 62 (2017), S.256-261 (DOI: http://dx.doi.org/10.1016/j.procir.2016.06.044)

 

 

 

Development of a software for planning the surgery of knee implants, corrective osteotomy as well as a system for standardized X-ray

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  • Partner: University of Leipzig (Department of Orthopedics, Trauma Surgery and Plastic Surgery), ISD - Internet Systems GmbH Dresden
  • Main objective: Development of a software for planning the surgery of knee implants, thereby the implant size and position can be precisely planned by means of a better X-ray imaging technique. A calibration method especially developed should guarantee the accuracy of the planning.
  • Contact:
  • Funded by: The Central Innovation Programme for SMEs by Federal Ministry for Economic Affairs and Energy.
  • Project duration: 01/04/2016 – 31/03/2018

For further information please click here.

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MERGE - Forming technology based on the operating media of the In-Situ production of metal / plastic structures

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  • Main Objective: Production of hybrid metal-plastic composites by using manufacturing technologies for metallic materials, especially, to make large-scale series productions for high-loaded hybrid structural components possible.
  • Contact:
  • Project duration: 01/11/2012 – 31/12/2018
  • Funded by: Deutsche Forschungsgemeinschaft (DFG)
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MERGE is focused on researching the implementation of plastic, textile and electronic elements by technology into efficient process chains for metallic basic structures.

Publications: see annual reports MERGE 2013 – 2016

For further information, pleases visit www.tu-chemnitz.de/MERGE/index.php


 

 

Development of self-regulating solar shading components for the building envelope based on thermal shape memory effect

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  • Partner: Bilfinger bauperformance GmbH, EnergieAutark GmbH, Cavertitzer Elektromontagen GmbH, Cavertitzer Elektromontagen GmbH, HTWK Leipzig
  • Main objective: An energy self-sufficient working shading system to diminish the energy requirement of room air-conditioning as well as to save the complete operation energy of buildings.
  • Contact:
    Dipl.-Ing. Inaki Navarro y de Sosa
  • Project duration: 01/06/2016 – 30/11/2017
  • Funded by: Bundesministerium für Bildung und Forschung, Förderprogramm „Zwanzig20 - Partnerschaft für Innovation“
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For this purpose, a thermosensitive actuator, which regulates the shading system according to environmental conditions, is to be developed on the basis of the shape memory effect. Concurrently, user interaction is to be partially allowed. For instance, in winter in order to provide demand-controlled glare shield, since overheat protection is not required.

Further information at www.smarthoch3.de/projekte


 

Development of a surgical suction-irrigation device made from shape memory alloy

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  • Partner: Zahntechnik Leipzig, Asklepios Klinik, Universitätsklinikum Leipzig, Städtisches Klinikum Dresden Friedrichstadt
  • Main objective: Development of a controller for a shape memory alloy (SMA) suction-irrigation device, which combines suction and irrigation functions into a single unit
  • Contact:
    Constanze Neupetsch, M.Eng.
  • Project duration: 01/07/2016 – 31/03/2017
  • Funded by: Joint project within the Twenty20 Alliance Smart³
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suction-irrigation device

 

video of suction-irrigation device

The development should be used in the otolaryngology-, oral and maxillofacial as well as neurological surgery. This enables the surgeon to activate a predefined geometrical form of the instrument using a button.

Further information at www.smarthoch3.de/projekte


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