Drückwalzen als inkrementelles Umformverfahren ist aufgrund seiner Verfahrenscharakteristik mit sehr hohen Rechenzeiten bei der Finite-Elemente-Methode (FEM) verbunden. Die Modelle ModIni und FloSim sind zwei analytisch-elementare Ansätze, um dieser Prämisse entgegenzuwirken. Das für ModIni entwickelte Geometriemodell wird in der vorliegenden Arbeit weiterentwickelt, so dass eine werkstoffunabhängige Berechnung der Staugeometrie ermöglicht wird und ein deutlich größeres Anwendungsspektrum der Methode bereitsteht. Die Simulationsmethode FloSim basiert auf dem oberen Schrankenverfahren und ermöglicht somit eine Berechnung von Zylinderdrückwalzprozessen innerhalb weniger Minuten. Für die Optimierung der Methode FloSim wurden in der vorliegenden Arbeit die analytischen Grundlagen für die Berechnung der Bauteillänge sowie der Umformzonentemperatur während des Prozesses erarbeitet. Weiterhin wurde auf Basis von numerisch realisierten Parameteranalysen ein Ansatz für die analytische Berechnung des Vergleichsumformgrades von Drückwalzprozessen entwickelt. Diese drei Ansätze, zu Bauteillänge, Temperatur und Umformgrad wurden in die Simulationssoftware FloSim integriert und führen zu einer deutlichen Genauigkeitssteigerung der Methode. / Flow Forming as incremental forming process is connected with extreme long computation times for Finite-Element-Analyses. ModIni and FloSim are two analytical/elementary models to antagonize this situation. The geometry model, which was developed for ModIni, is improved within the presented work. The improvement enables the material independent computation of the pile-up geometry and permits a wider application scope of ModIni. The simulation method FloSim is based on the upper bound method, which enables the computation of cylindrical Flow Forming processes within minutes. For the optimization of the method FloSim, the basics for the analytical computation of the workpiece length during the process and the computation of the forming zone temperature were developed within this work. Fur-thermore, an analytical approach for the computation of the equivalent plastic strain of cylindrical Flow Forming processes was developed based on numerical parameter analyses. This tree approaches for computing the workpiece length, the temperature and the equivalent plastic strain were integrated in FloSim and lead to an increased accuracy.

Unternehmen stehen zunehmend vor der Herausforderung, dem drohenden Wissensverlust durch demografischen Wandel und Mitarbeiterabgang zu begegnen. In Zeiten voranschreitender Digitalisierung gilt es, große Datenmengen beherrschbar und nutzbar zu machen, mit dem Ziel, einerseits die Ressourceneffizienz innerhalb des Unternehmens zu erhöhen und anderseits den Kunden zusätzliche Dienstleistungen anbieten zu können. Vor dem Hintergrund, ein effizientes Qualitätsmanagement und eine vorausschauende Instandhaltung mit ein und demselben System zu realisieren, sind zunächst technologische Kennzahlen und die Prozessführung zu bestimmen. Im Bereich der intelligenten Instandhaltung ist es jedoch nicht immer möglich, Fehlerzustände von physischen Anlagen im Serienbetrieb als Datensatz abzufassen. Das bewusste Zulassen von Fehlern unter realen Produktionsbedingungen könnte zu fatalen Ausfällen bis hin zur Zerstörung der Anlage führen. Auch das gezielte Erzeugen von Fehlern unter stark kontrollierten Bedingungen kann zeitaufwendig, kostenintensiv oder sogar undurchführbar sein.

Companies are increasingly challenged by the impending loss of knowledge due to demographic change and employee loss. In times of advancing digitalization, it is important to make large datasets accessible and usable, aiming at increasing resource efficiency within the company on the one hand and being able to offer customers additional services on the other. Given the background of implementing efficient quality management and predictive maintenance with the same system, technological key figures and process control must first be determined. In the field of intelligent maintenance, however, it is not always possible to record error states of physical systems in series operation as a data set. Deliberately allowing faults to occur under real production conditions could lead to fatal failures or even the destruction of the system. The targeted generation of faults under highly controlled conditions can also be timeconsuming, cost-intensive, or even impractical.

Das Formdrücken findet seine industrielle Anwendung in der Herstellung rotationssymmetrischer Hohlbauteile für kleine und mittlere Losgrößen. Diese Bauteile werden häufig in einem weiteren Verfahrensschritt als Vorform für die Herstellung profilierter Hohlkörper genutzt. Verfahrensbedingt tritt bereits bei der Vorformherstellung eine ungewollte Blechdickenabnahme auf. Um diese Blechdickenabnahme zu minimieren, wurde anhand numerischer Methoden das Verfahren des Rotationsschwenkbiegens an der Professur Virtuelle Fertigungstechnik der TU Chemnitz entwickelt. Das Prinzip dieses inkrementellen Umformprozesses basiert auf einer Verfahrenskombination des konventionellen Drückens und des Schwenkbiegens, mit dem Ziel der faltenfreien Herstellung von Hohlbauteilen bei gleichzeitiger minimaler Blechausdünnung. Die als Halbzeug verwendete Ronde wird zu Beginn des Prozesses auf eine formgebende Matrize gespannt und in Rotation versetzt. Durch die Schwenkbewegung eines zylindrischen Umformwerkzeuges wird das ebene Blech an die Kontur der Matrize angelegt, wobei keine Relativbewegung zwischen Blech und Werkzeug stattfindet. Demzufolge entstehen minimale Zugspannungen in der Blechebene und die Blechausdünnung wird deutlich verringert. Durch die Durchmesserreduzierung bilden sich jedoch ebenso tangentiale Druckspannungen aus, welche zu einer ungewollten Faltenbildung führen können. Im Rahmen des Vortrages werden anhand von FEM-Simulationen Möglichkeiten vorgestellt, um diese Druckspannungen zu reduzieren oder gezielt zur Vorformherstellung für profilierte Hohlbauteile zu nutzen.

O trabalho aborda o estudo e o desenvolvimento de um interferômetro sensor de alta tensão, baseado em célula Pockels (modulador eletro-óptico) na topologia reflexiva (\"double pass\") e que é parte integrante de um Transformador de Potencial Óptico (TPO), que utiliza sistema interferométrico de luz branca (WLI-White Light Interferometry), que está sendo desenvolvido pelo grupo do Laboratório de Sensores Ópticos (LSO) do PEA-EPUSP, e é capaz de medir diretamente tensões presentes em sistema elétrico de potência (SEP) classe 69kVRMS. Para desenvolver o tema proposto foi feita uma revisão da literatura baseada em livros, artigos e teses para identificar topologias em moduladores eletro-ópticos transmissiva (\"single pass\") e reflexiva (\"double pass\") para definir o tipo de modulador mais adequado para a aplicação em questão. A partir dos estudos e implementações realizadas, verificou-se um enorme potencial para o desenvolvimento e aplicação da topologia \"double pass\" no sensor interferométrico da célula de alta tensão do TPO. A topologia mostrou-se vantajosa em relação aos protótipos dos TPOs desenvolvidos anteriormente, a partir de características tais como: a facilidade de recurso de alinhamento do feixe de luz, construção e reprodução relacionados ao cristal eletro-óptico, diminuição do número de componentes ópticos volumétricos e aumento da rigidez dielétrica da célula sensora. Simulações computacionais foram realizadas mediante a aplicação do método dos elementos finitos (MEF) que contribuíram para o auxílio do projeto da célula sensora, particularmente, para estimativa do valor da voltagem de meia onda, V?, parâmetro importante para o projeto do TPO. Um protótipo do TPO com célula sensora de alta tensão reflexiva foi implementado e testado no laboratório de alta tensão do IEEUSP a partir de ensaios com tensões nominais de 69kVrms a 60Hz e máxima de 140kVrms a 60 Hz. Como resultado deste trabalho, amplia-se o conhecimento e domínio das técnicas de construção de interferômetros sensores de alta tensão na topologia reflexiva aplicadas a TPOs. / This work describes the study and development of a high-voltage interferometer sensor based on Pockels cell (electro-optical modulator) in the reflective topology (double pass), which is part of an optical potential transformer (OPT) using a white light interferometry system (WLI) being developed by the Optical Sensors Laboratory (LSO) group from PEA-EPUSP, which is able to directly measure power electrical system (PES) voltages for the 69kVrms class. To develop the work, a bibliographic review was made on books, papers and theses in order to identify electro-optical modulators related to transmissive (single pass) and reflective (double pass) topologies aiming at defining the most appropriate modulator type for the present application. From the studies and implementations performed, it was realized that there is a huge potential for the development and application of \'double pass\' topology in the OPT high-voltage interferometric sensor. This topology showed to be advantageous compared to previously developed OPT prototypes for characteristics such as: ease of beam alignment feature, construction and reproduction related to the electro optical crystals, decrease of volumetric optical components number and increase of the sensor cell dielectric strength. Computer simulations were performed by applying the Finite Element Method (FEM) that contributed to the sensor cell design, particularly in estimating the half-wave voltage value, V?. The OPT with the reflective high-voltage sensing cell was implemented and tested at the high voltage laboratory of IEE-USP for the 69kVrms at 60Hz nominal voltage and the 140kVrms at 60Hz maximum voltage. As a result of this work, nationwide expertise over the techniques of construction of high-voltage interferometer sensors in reflective topology applied to OPTs was achieved and knowledge was broadened.

O trabalho aborda o estudo e o desenvolvimento de um interferômetro sensor de alta tensão, baseado em célula Pockels (modulador eletro-óptico) na topologia reflexiva (\"double pass\") e que é parte integrante de um Transformador de Potencial Óptico (TPO), que utiliza sistema interferométrico de luz branca (WLI-White Light Interferometry), que está sendo desenvolvido pelo grupo do Laboratório de Sensores Ópticos (LSO) do PEA-EPUSP, e é capaz de medir diretamente tensões presentes em sistema elétrico de potência (SEP) classe 69kVRMS. Para desenvolver o tema proposto foi feita uma revisão da literatura baseada em livros, artigos e teses para identificar topologias em moduladores eletro-ópticos transmissiva (\"single pass\") e reflexiva (\"double pass\") para definir o tipo de modulador mais adequado para a aplicação em questão. A partir dos estudos e implementações realizadas, verificou-se um enorme potencial para o desenvolvimento e aplicação da topologia \"double pass\" no sensor interferométrico da célula de alta tensão do TPO. A topologia mostrou-se vantajosa em relação aos protótipos dos TPOs desenvolvidos anteriormente, a partir de características tais como: a facilidade de recurso de alinhamento do feixe de luz, construção e reprodução relacionados ao cristal eletro-óptico, diminuição do número de componentes ópticos volumétricos e aumento da rigidez dielétrica da célula sensora. Simulações computacionais foram realizadas mediante a aplicação do método dos elementos finitos (MEF) que contribuíram para o auxílio do projeto da célula sensora, particularmente, para estimativa do valor da voltagem de meia onda, V?, parâmetro importante para o projeto do TPO. Um protótipo do TPO com célula sensora de alta tensão reflexiva foi implementado e testado no laboratório de alta tensão do IEEUSP a partir de ensaios com tensões nominais de 69kVrms a 60Hz e máxima de 140kVrms a 60 Hz. Como resultado deste trabalho, amplia-se o conhecimento e domínio das técnicas de construção de interferômetros sensores de alta tensão na topologia reflexiva aplicadas a TPOs. / This work describes the study and development of a high-voltage interferometer sensor based on Pockels cell (electro-optical modulator) in the reflective topology (double pass), which is part of an optical potential transformer (OPT) using a white light interferometry system (WLI) being developed by the Optical Sensors Laboratory (LSO) group from PEA-EPUSP, which is able to directly measure power electrical system (PES) voltages for the 69kVrms class. To develop the work, a bibliographic review was made on books, papers and theses in order to identify electro-optical modulators related to transmissive (single pass) and reflective (double pass) topologies aiming at defining the most appropriate modulator type for the present application. From the studies and implementations performed, it was realized that there is a huge potential for the development and application of \'double pass\' topology in the OPT high-voltage interferometric sensor. This topology showed to be advantageous compared to previously developed OPT prototypes for characteristics such as: ease of beam alignment feature, construction and reproduction related to the electro optical crystals, decrease of volumetric optical components number and increase of the sensor cell dielectric strength. Computer simulations were performed by applying the Finite Element Method (FEM) that contributed to the sensor cell design, particularly in estimating the half-wave voltage value, V?. The OPT with the reflective high-voltage sensing cell was implemented and tested at the high voltage laboratory of IEE-USP for the 69kVrms at 60Hz nominal voltage and the 140kVrms at 60Hz maximum voltage. As a result of this work, nationwide expertise over the techniques of construction of high-voltage interferometer sensors in reflective topology applied to OPTs was achieved and knowledge was broadened.

Zirconium alloys (zircaloy) have been widely used in light water reactors due to their good thermomechanical properties, corrosion resistance, and low thermal neutron absorption rate. As one of the most important safety barriers, cladding is not only used to encapsulate nuclear fuel, but also to prevent the nuclear fission products from leaking into the coolant. During the operation of nuclear reactors, hydride will form in zircaloy and significantly degrade the tensile strength, ductility, fracture toughness, and creep behavior of the cladding, and eventually leading to the failure of cladding. Therefore, understanding the material properties of zircaloy and its hydrides is crucial to the safety of power plants. In this study, the mechanical Raman spectroscopy and nano-mechancial testing techniques were used to perform thermomechanical measurements and damage analysis of zircaloy-4. The Raman thermometry method was used to measure localized spatially resolved thermal conductivity and establish the potential linkage of microstructure to thermal and mechanical properties of zircaloy-4. The local thermal conductivity values showed to increase with increase in grain size. Nanoindentation and nano-scale impact techniques were used to obtain the viscoplastic constitutive relation of hydrides at elevated temperatures. Based on the obtained viscoplastic model, fracture strength of hydrides was predicted by using finite element method (FEM) simulations. An extended Gurson-Tvergaard-Needleman (GTN) model was used to study the macro-scale fracture behavior of hydrided zircaloy-4 structures. Good agreement between calculated and experimental results was obtained for various boundary conditions.

Es wurden die Mikrostruktur und die mechanischen Eigenschaften bedingt durch dehnungsinduzierte Martensitbildung im metastabilen austenitischen Stahl X5CrNi18.10 und in einem niedrig legierten Mn-Si-Al Stahl untersucht. Dazu wurden Zugversuche bei verschiedenen Temperaturen durchgeführt. Für den Stahl X5CrNi18.10 wird auf der Grundlage der Arbeit von Ludwigson und Berger ein Modell zur Beschreibung des Umwandlungsverhaltens als Funktion der Dehnung und der Temperatur entwickelt. Es kann weiterhin gezeigt werden, dass die erreichbare Gleichmaßdehnung in diesen Stahl durch eine maximal ertragbare Umformarbeit bestimmt wird. Die erhaltenen Fließkurven konnten mit Hilfe der FEM und einer modifizierten Mischungsregel für die Festigkeit erfolgreich modelliert werden. Die Ergebnisse für den Mn-Si-Al Stahl zeigen, dass neben dem Restaustenit, das Verbundverformungsverhalten der anderen Gefügebestandteile (Ferrit, Bainit, Martensit) wichtige Faktoren für die Optimierung der mechanischen Eigenschaften darstellen.

<div> <div> <div> <p>Composite materials have become widely used in engineering applications, in order to reduce the overall weight of structures while retaining their required strength. Due to their light weight, relatively high stiffness properties, and formability into complex shapes, discontinuous fiber composites are advantageous for producing small and medium size components. However, qualifying their mechanical properties can be expensive, and therefore there is a need to improve predictive capabilities to help reduce the overall cost of large scale testing. To address this challenge, a composite material consisting of discontinuous glass fibers in a polypropylene matrix is studied at the microstructural level through coupled experiments and simulations, in order to uncover the mechanisms that cause microvoids to initiate and progress, as well as certain fiber breakage events to occur, during macroscopic tension. Specifically, this work coupled in-situ X-ray micro computed tomography (μ-CT) experiments with a finite element simulation of the exact microstructure to enable a 3D study that tracked damage initiation and propagation, and computed the local stresses and strains in the microstructure. In order to have a comprehensive 3D understanding of the evolution of the microstructure, high fidelity characterization procedures were developed and applied to the μ-CT images in order to understand the exact morphology of the microstructure. To aid in this process, ModLayer - an interactive image processing tool - was created as a MATLAB executable, and the 3D microstructural feature detection techniques were compared to traditional destructive optical microscopy techniques. For damage initiation, this work showed how high hydrostatic stresses in the matrix can be used as a metric to explain and predict the exact locations of microvoid nucleation within the composite’s microstructure. From a damage propagation standpoint, matrix cracking - a mechanism that has been notably difficult to predict because of its apparent stochastic nature - was studied during damage propagation. The analysis revealed the role of shear stress in fiber mediated flat matrix cracking, and the role of hydrostatic stress in fiber-avoidance conoidal matrix cracking. Overall, a sub-fiber simulation and an in-situ experimental analysis provided the microstructural physical phenomena that govern certain damage initiation and progression mechanisms, further enabling the strength and failure predictions of short fiber thermoplastic composites. </p></div></div></div>

This thesis examines influence of thermal shock on fatigue of pressure equipment components. The paper relates to project of IMI CCI Brno, which is a leading manufacturer of valves for the energy and process industries. Analysis concerns the impact of thermal shock concentrating on high pressure part of the steam valve. And proposal for a new valve geometry that reduces machining operations and reduce financial costs of production. First part of the thesis presents a basic review of fatigue damage components concerning mechanical loading and thermal – mechanical loading. Second part of the study creates FEM model of the valve. FEM model simulate temperature field and stress during thermal shock. Influence of thermal shock to fatigue damage was computed on basis of stress tensor obtained from FEM simulation under Chapter 18 of the standard EN 13445-3. Existing valve geometry was verified and the new geometry was proposed that simplified and reduce financial costs of production.