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In der Verpackungsindustrie werden Becher und Schalen u.a. mittels Druckluftformautomaten aus Folienbahnen geformt. Die Kiefel GmbH ist Hersteller solcher Anlagen zum Umformen aus Kunststoffhalbzeugen mittels Warmumformprozessen. Die Herausforderung an die Bewegungstechnik besteht bei diesem Prozess darin, die Taktzeiten möglichst gering zu halten und somit die Produktionsrate zu erhöhen. In der KTR Baureihe der Kiefel GmbH wird die Werkzeugbewegung hauptsächlich über zwei Komponenten bestimmt. Die Geometrie der Bewegungsbahn wird über Kurvenscheiben vorgeschrieben. Der zeitliche Verlauf der Bahn wird über die Drehgeschwindigkeit der Kurvenscheiben mittels eines Servoantriebes variiert. Auch wenn die Kombination von Kurvenscheibe und Servoantrieb verschiedene Vorteile bietet, ist die optimale Synthese beider Komponenten noch unzureichend erforscht. Innerhalb einer Kooperation vom Institut für Getriebetechnik, Maschinendynamik und Robotik (IGMR) der RWTH Aachen University und der Kiefel GmbH wurde das Potential von servogesteuerten Kurvengetrieben für die Flexibilisierung des Tiefziehprozesses untersucht. Dabei sind neue Ansätze zur Auslegung des Gesamtsystems entstanden. Ergebnisse dieser Untersuchung werden innerhalb dieser Veröffentlichung dargestellt. Dabei wird zuerst auf den Thermoformprozess eingegangen, bevor das generelle Potential servogesteuerter Kurvengetriebe beschrieben wird. Anschließend wird ein kleiner Einblick in den gemeinsam entwickelten Auslegungsprozess gegeben. [... aus der Einleitung]

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<p>The properties and microstructure of Ti-5Al-5V-5Mo-3Cr were characterized under various stress states after the following heat treatments: 1) annealing above the β transus, followed by cooling at various rates and ageing for different times; 2) solution heat treatment in the α-β range, fan-cooling and ageing for various temperatures and times.</p> <p>Heat treatment above the ptransus temperature causes complete recrystallization of the as-forged microstructure. The as-cooled microstructure consists of equiaxed β grains with an average grain size of 200μm. Water quenching from above the β transus results in precipitation of a dispersion of nano-sized ω phase; while the fan-cooled microstructure contains nano-sized ω and α precipitates. Ageing of the fan-cooled microstructure at 790°C or 600°C precipitates sub micron acicular α throughout the β grains. The tensile properties of this condition could not be determined using standard tensile specimens due to brittle failure at the grips.</p> <p>Controlled cooling from above the β transus to the ageing temperature at slower rates produces a coarser α+β microstructure. Acicular α laths are produced with cooling rates of 1°C/min, while lamellar α develops at cooling rates of 3.4°C/min. The β annealed and fan-cooled condition is characterized by relatively low strength (~850MPa) and low ductility (~6% elong.).The fracture mode is by intensely localized slip and the creation of transgranular cracks. Localization of slip is attributed to shearing of the nano-scale ω precipitates by dislocations. A linear relationship between the grain size, d⁻¹/² , and the yield and fracture stresses was established, as described by the Hall-Petch relation. With controlled cooling, the strength and ductility improve by precipitation of lamellar α within the β matrix. Improvements in ductility and strength are achieved by reducing the slip length.</p> <p>Solution heat treatment below the β transus and fan-cooling results in complete dissolution of the as-forged acicular α phase. Solutionizing at 50°C below the ptransus yields a volume fraction of 16.5% primary α in a matrix of retained β. Low angle grain boundaries and globular primary α, each measuring 2-4μm average in diameter, are uniformly distributed throughout the retained β matrix. The tensile strength in this condition is relatively low, i.e. (900MPa) and the ductility relatively high (~16% elong.). With ageing in the 500°C to 600°C temperature range, precipitation of α within the retained β begins within 5 minutes of the start of ageing. Precipitating is heterogeneously nucleated at dislocations and grain boundaries. The yield and ultimate tensile strengths reach values of roughly 1200 and 1300MPa, respectively, and remain relatively constant for up 48 hours ageing</p> <p> The fracture stresses for the solution treated condition and for material subsequently aged at 500°C and 600°C are quite similar in magnitude. This similarity is due to the fact that the fracture mechanism, which controls the fracture stress, is the same for all these conditions. The fracture mechanism for all the solution treated conditions begins with shear decohesion of the primary α/β interfaces.</p> <p>For each condition, the damage mechanisms and final fracture modes were evaluated and rationalized on the basis of microstructural features. The yield and fracture stresses for the various conditions were calculated and plotted on a two-principal stress axis coordinate system, thus creating the failure envelope for Ti-5553. For the β annealed and fan cooled and for the α-β solution heat treated and aged conditions the yield and fracture envelopes are two concentric ellipses in good agreement with the shear strain energy (van Mises) model for failure.</p> <p>The fracture toughness and stress corrosion cracking behaviour for the STA condition were evaluated and compared against other β titanium alloys.</p> / Thesis / Doctor of Philosophy (PhD)

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