Wagner, Christian ; Gramlich, Sebastian ; Monnerjahn, Vinzent ; Groche, Peter ; Kloberdanz, Hermann (2015)
Technology pushed process and product innovation – Joining by Linear Flow Splitting.
CIRPe 2015 - Understanding the life cycle implications of manufacturing.
Konferenzveröffentlichung, Bibliographie

Kurzbeschreibung (Abstract)

In order to take full advantage of manufacturing technologies, designers have to use the technology specific manufacturing-induced properties. Often, product functions can be further improved by adequate selection and optimisation of the manufacturing technology. Furthermore, a consequent combination of product and process development can lead to product innovations. Due to the mechanisms of severe plastic deformations occurring in some metal forming processes, linear flow splitting yields ultra fine grained (UFG) microstructures which are characterised by high hardness, ductility and fatigue strength. These manufacturing-induced material properties are particularly suited for rolling contact areas. Therefore, linear guiding systems are potential products for linear flow split profiles. Multi-functional linear systems require the integration of additional functional elements into the profiles. Since linear flow splitting is a cost effective continuous manufacturing process it seems attractive to integrate the necessary joining of profiles and functional elements into the continuous operation. Even more preferable would be the use of the mechanisms acting during the forming process for the activation of the joining operation. The paper at hand introduces a mechanical joining process following this technology push approach. Thereby, manufacturing-induced properties and mechanisms induced during the linear flow splitting process are utilised to integrate additional functional elements. The mechanical conditions occurring during a linear flow splitting operation are used for the joining process. Hereby, necessary joining operations can be integrated into the continuous flow production, maintaining the technological potential to manufacture large quantities at low costs. Extensive experiments show the applicability of various joined elements and materials for process integrated mechanical joining. Additionally, design measures are identified to optimise the joining and separating forces in relation to specific applications. The potential for product innovations due to lightweight and cost reduction by process integrated mechanical joining is illustrated by an innovative linear system. Its core component is an integrated rack as part of a rack and pinion drive. The realised linear system is used in a facade cleaner.

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