focus: manufacturing science - ivp · virtual planning quelle audi in the mass production the...

|| 23.04.2015Focus specialization at IVP 1

Focus: Manufacturing Science - IVP

Institute of Machine Tools and Manufacturing Prof. Dr. Konrad Wegener

Institute of Virtual Manufacturing Prof. Dr. Pavel Hora

http://www.ivp.ethz.chhttp://www.iwf.mavt.ethz.ch

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Industrial application fields of forming technologies and

their virtual planning methods

What you can learn in the IVP research fields

Lectures

Bachelor thesis MaS Industrial Internships

23.04.2015Focus specialization at IVP 2

Content

||

Automotive industry

Food & pharmaceutical packaging

Electronics assembly

Components of household appliances

Medical technology

Aircraft industry

Semi-finished parts (sheet metal, profiles,

tubes, wire)

23.04.2015Focus specialization at IVP3

Influence of production numbers on

manufacturing process

Large scale production

Forming and master forming

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Forming processes

There are about 230 different forming processes ….

Focus specialization at IVP23.04.2015

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Virtual planning

Quelle AUDI

In the mass production the virtual

process optimization is a “MUST “

STEPS

Process design

Process optimization

Process robustness

Forming Process Manufacturing Process Assembling


||Focus specialization at IVP6

“Production” knowledge

23.04.2015

||7

“Simulation” knowledge

Selection of the

forming method

Selection of the

forming method

Experimental methods

for the detection of

material properties


for the detection of

material properties

Constitutive modelConstitutive model

FEM model

(numerical methods)

FEM model

(numerical methods)

Optimization of

the

Process

Optimization of

the

Process

Tool topology

(CAD)

Tool topology

(CAD)


||Focus specialization at IVP 8

m

mm

µm

nm

Virtual Models

Process modeling on

different scales …

23.04.2015

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Lectures



Content


Focus topic I: «Forming Technologies»

ProcessesProcesses

Constitutive

Models

Constitutive

Models

MaterialsMaterials

Numerical

Methods

Numerical

Methods

Software

development• Nonlinear-FEM

• Planning

systems

Software


• Planning

systems

Virtual process

modeling• Material behavior

• Failure prediction

• Robustness

Virtual process



• Robustness

Forming

technologies

Forming

technologies

06.05.2015 Prof. P. Hora, IVP, ETH Zürich 11

Technopark - ViProLab

Process

Tools

M-Systems

06.05.2015 Prof. P. Hora, IVP, ETH Zürich 12

Thermal forming processes

Development of high strength steels by ETG processes

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../../../Videos_all/Videos_DLD/dieless.avi

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Focus topic II «Virtual process modeling»

Forming

technologies

Forming

technologies


ProcessesProcesses

Constitutive

Models

Constitutive

Models

MaterialsMaterials

Numerical

Methods

Numerical

Methods

Software


• Planning

systems

Software


• Planning

systems

Virtual process



• Robustness

Virtual process



• Robustness

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Optimal product / tool behavior depends on the

material selection


Materials

|| Folie 15/

Umformtechnik-4

Plastic flow behavior of materials

The parts will be produced by plastic forming

||16

Dim I - Materialwahl im Maschinenbau - Teil 1

„Strain Hardening“(Kaltverfestigendes geschichtsabhängiges Verhalten)


IVP experimental equipment

Tensile test Torsion test Bulge test Tube test

|| 23.04.2015Focus specialization at IVP

18

Plastic flow of metallic materials and failure

under large strains

The knowledge of how to describe the behavior of materials is an

essential part of the engineering education

Constitutive

models

Failure

predictionFriction

Experimental

Methods

klijklij ED

Elasto-plastic flow

behavior

Hardening behavior

Anisotropy

Temp. dependency

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Constitutive modelsComplex constitutive models in metal forming


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Challenges in material modeling

Prediction of multistep-process behavior

Forming IThermal

treatmentForming IIM(0) M(k)

Initial material conditions Final material conditions

,...),,()0( Th eqeq )()0( ji

F

Crash behavior ?



Master topic III «Technical software development»

Numerical

Methods (FEM)

Numerical

Methods (FEM)

Programming

skills C, C++

Programming

skills C, C++

User interfacesUser interfaces

Process

understanding

Process

understanding

IVP

FEM Softaware

IVP has the experience of professional FEM

development

Forming

technologies

Forming

technologies

Virtual process



• Robustness

Virtual process



• RobustnessSoftware


• Planning

systems

Software


• Planning

systems


«special purpose» FEM codes developed at IVP

Fine blankingPress hardening Extrusion


Your professional competences ….

Predefinition of the

forming method


forming method


for the measurement of

material properties



material properties


FEM model

(numerical methods)

FEM model

(numerical methods)

Optimization of the

Process

Optimization of the

Process

Tool topology

(CAD)

Tool topology

(CAD)

At the end you will have an

integral knowledge, which allows

you the layout of manufacturing

processes

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Lectures



Content


Bachelor «Focus» lectures


forming method


forming method



material properties



material properties


FEM model

(numerical methods)

FEM model

(numerical methods)

Optimization of the

Process

Optimization of the

Process

Tool topology

(CAD)

Tool topology

(CAD) Umformtechnik IIUmformtechnik II

Umformtechnik I Basics & Materials

Umformtechnik II Numerical methods

Umformtechnik III Forming processes

Umformtechnik I Basics & Materials

Umformtechnik II Numerical methods

Umformtechnik III Forming processes

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Manufacturing science: IWF and IVP

Lectures IVP

Dimensionieren I

Focus

Umformtechnik I – Grundlagen der Umformtechnik

Umformtechnik II – Simulation umformtechnischer

Prozesse

Umformtechnik III – Umformtechnische Verfahren

Master lectures

Methoden der virtuellen Prozessauslegung

umformtechnischer Systeme

Principles of nonlinear finite element methods

Principles of FEM based optimization and robustness

analysis

Computational Methods in Micro and Nano Structures

Lectures IWF

Werkstoffe und Fertigung I und II

Dimensionieren II

Fertigungstechnik I und II

Produktionsmaschinen I und II

Qualität von Werkzeugmaschinen - Dynamik, Mikro-

und Submikromesstechnik

Produktion von elektrischen und elektronischen

Komponenten

Mechanische Produktion: Montieren, Fügen,

Beschichten

Methods and Tools for the Development of Structured

Mechatronic Products

Betriebliche Simulation von Produktionsanlagen

Visualisierung, Simulation und Interaktion VR 1+2

Umweltmanagement

Prof. Dr. Konrad WegenerInstitute of Machine Tools and Manufacturing

Prof. Dr. Pavel Hora Institute of Virtual Manufacturing

++


||




Lectures



Content

||Focus specialization at IVP28

IVP covers research fields in

Material

models• TRIP

• ETG

• PH

• HAH

• LD-FLC

Material

models• TRIP

• ETG

• PH

• HAH

• LD-FLC

ALE-

FEM

ALE-

FEM

Planning tools• FEINTOOL

• ETG

• AF-Cost-

Calculator

Planning tools• FEINTOOL

• ETG

• AF-Cost-

Calculator

Q-GuardQ-GuardCTT

• Friction

models

• New test

CTT• Friction

models

• New test

Sensors• EC-Mat

• DB-Force

Sensors• EC-Mat

• DB-Force

23.04.2015

||Focus specialization at IVP 29

International scientific relations Germany

RWTH Aachen

Prof. Hirt, IBF

Prof. Bleck, IEHK

Prof. Klocke, Fraunhofer Institut, IPT

TU-Munich, Prof. Volk, UTG

TH Karlsruhe, Prof. Schweizerhof

TU Berlin, Dr. K. Müller, SPZ-Berlin

Uni Stuttgart, Prof. Liewald, IFU

Uni Dortmund, Prof. Tekkaya, IUL

Uni Bayreuth, Prof. Emmerich, PSI

Netherlands University of Twente, Prof. Huetink

France Ecole des Mines de Paris, Prof.

Massoni, Prof. Chenot

Univ. of Franche Comté, Prof. Gelin

US

Ohio State Univ., Prof. Wagoner

MIT, Prof. O. de Weck

Golden Univ., Prof. J. Van Tyne

Japan

Osaka Inst. of Technology OIT, Prof. E. Nakamachi

Hiroshima, Prof. Yoshida

Tokyo Univ.,Prof. Kuwabara, TUAT

Korea

KAIST, Prof. D.Y. Yang

POSTECH, Prof. F. Barlat

China

Shiatong Univ., Prof. Ruan

23.04.2015

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Leading Swiss Forming Companies

CH-Options for your later job … (many more)


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240 km240 km

266 km266 km166 km


6-May-15Prof. P. Hora, IVP, ETH Zürich

Institute of Virtual Manufacturing

E N D

www.ivp.ethz.ch

Focus specialization at IVP 32

focus: manufacturing science - ivp · virtual planning quelle audi in the mass production the...

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