P 1278 - Improvement of the application behaviour of hot forming tools by nitriding-appropriate selection of hot work tool steels

P 1279 - Design recommendations for the material-efficient use of high-strength steel tubes and profiles in agricultural soil tillage machinery The demands on the performance of modern agricultural machinery and equipment are constantly increasing and the associated development is facing enormous challenges. In view of these development trends, there is a conflict of objectives between the required performance, the permissible machine weights and the economically available cost framework. This problem is addressed in the project and investigated on the basis of agricultural soil tillage machines, which include, for example, rotary tillers, cultivators, harrows and ploughs. These tillage machines offer great potential for the lightweight-optimised and material-efficient use of high-strength steels, as they are profile-intensive constructions in which standard materials (e.g. S355) are traditionally used. The design is usually still based on experience without knowledge of the exact loads, which makes it difficult to optimise the design to suit the material. As part of the research project, an equivalent test collective for soil tillage equipment is being created. The basis for this is formed by realistic measurement runs with a soil tillage implement. The test collective forms the basis for the operational design of agricultural tillage equipment. Parallel to the determination of the load spectrum, fatigue strength tests are carried out on three design details that frequently occur in agricultural machinery, as well as on a sample component. Based on the experimental results, a notch case recommendation is developed for these details. Numerical parameter studies are used to vary key geometric parameters so that the results of the numerical analyses provide corresponding formulae that enable the stress concentration factors for the underlying construction details to be determined. Publication: 2021 Authors: Prof. Dr.-Ing. T. Ummenhofer, Prof. Dr.-Ing. Ch. Schäfers

P 1273 - Development of an intelligent setup assistance system for straighteners to extend the process limits of processing high-strength wire materials The steel processing industry is characterised by 79% small and medium-sized companies with fewer than 100 employees. These companies generate a turnover of 79.8 billion euros, of which around 43 % is accounted for by preliminary products such as cold-rolled strip, drawn wire and sheet metal and forged parts [BMW15]. These preliminary products are usually supplied as strip material, wound onto coils. In a high-wage country such as Germany, efficient further processing is only possible with a high degree of automation in production. The material properties of the semi-finished product vary over the length of the coil. This affects the geometry, hardness, modulus of elasticity, pre-curvature and yield strength. These fluctuations are countered with the development of an intelligent, self-correcting levelling device. This can react to fluctuations in semi-finished products during the process. In order to be able to detect these fluctuations online during the process, investigations have been carried out into the sensor and actuator technology. In particular, the developed online measurement of the flat wire curvature enables a straightening strategy adapted to the fluctuations/changes in the semi-finished product. From this, a design system for the newly developed intelligent self-correcting straightener has been developed. Through fundamental experimental and numerical investigations, a validated numerical model was used to create a basis for identifying relevant process parameters. These process parameters could be investigated in isolation, whereby it was shown, for example, that the deformation capacity could be maximised for the subsequent process by applying a straightening strategy of the semi-finished product optimised with a few alternating bends, thus considerably strengthening the competitiveness of steel compared to non-ferrous metals due to the maximised remaining deformation capacity. Publication: 2021 Authors: Prof. Dr.-Ing. habil. A. Trächtler, Prof. Dr.-Ing. W. Homberg

P 1272 - Experimental and numerical investigation of the damping properties of bonded structures under dynamic loading A large number of structures from the field of steel construction, such as bridge structures, support structures for wind turbines and mast and observation tower structures, as well as from the fields of (vibration) mechanical engineering and automotive engineering are exposed to dynamic excitations during their operation. These dynamic excitations often result from environmental influences or the regular operation of a machine or an automobile and lead to structural vibrations in the respective construction, which in turn are accompanied by increased structural stresses. Adhesives based on epoxy resins and polyurethanes can be modified in such a way that, in addition to excellent strength, they also have good damping properties. The viscoelastic material behaviour of the adhesive creates material damping, which contributes to structural damping. However, it has not yet been clarified how dynamically stressed structures with adhesive bonds can be optimally designed in order to utilise the advantageous damping properties of viscoelastic adhesives in dynamic tuning. As part of the completed research project, the performance of bonded joints was therefore investigated and modelled with particular consideration of the damping properties. On the basis of mechanical and dynamic characterisation tests, a 2-component PU and a 2-component EP adhesive were selected for further investigations. In the context of vibration stress, there is a need to investigate the damping behaviour for the application areas of steel construction, automotive engineering, vibrating machinery and plant engineering. As part of the project, a new methodology was developed to take into account the damping properties of dynamically stressed structures. The focus is on both the experimental and numerical identification and characterisation of the damping properties of bonded joints. The development progress achieved can lead to an increase in efficiency and cost-effectiveness in the areas of steel, automotive, vibration machines and plant engineering. The aim of the research project was to develop a concept for the reliable calculation and assessment of the damping properties of dynamically stressed, bonded lap joints and plug-in connections. The concept should be applicable to constructions and structures from the steel, automotive, vibration machine and plant engineering industries. The following work was carried out for this purpose: - Characterisation of suitable materials (steel grades and adhesives) as well as bonded connection details from the fields of steel construction, automotive construction, vibration and plant engineering. - Investigation of the damping potential using numerical calculations on realistic structures. - Identification of relevant material parameters and development and validation of the material model to describe the damping behaviour of the adhesives The following results were achieved: - Quantification of the damping potential of bonded technological and component-like test specimens - Identification of the influence of different geometry and test conditions on the damping properties of the analysed test specimens - Successful development and validation of material models of the adhesives: the experimentally determined damping properties can be predicted using numerical simulations. Publication: April 2022 Authors: J. Damm, M. Albiez, Prof. T. Ummenhofer, J. Göddecke, Prof. G. Meschut, F. Kötz, Prof. A. Matzenmiller

P 1271 - Application of the structural stress concept for steel structures subjected to fatigue loading This final report on the application of the structural stress concept to steel structures subjected to fatigue stress deals with structural stress-orientated evaluation approaches for the notch details of longitudinal stiffeners, transverse stiffeners and cross joints. The focus is particularly on the effects of manufacturing-related imperfections and thickness effects, which are investigated using suitable FE analyses and indirect stress increase factors. Extensive parameter studies on FE shell and solid models are carried out for this purpose. The numerical results are verified using our own experimental tests. For this purpose, static tensile and bending tests as well as experimental fatigue tests are carried out and analysed. On the one hand, the results can be used to verify the economic applicability of the structural stress concept compared to the nominal stress concept. On the other hand, specifications on the effects of imperfections and thickness effects can be determined, as some of the test series analysed are designed with intentional imperfections and different thicknesses. 3D laser scan measurements of all analysed test specimens enable a precise assessment of the imperfections present. In this way, stress concentration factors for the indirect determination of stress-increasing effects can be precisely determined and existing regulations can be verified. The results show that the structural stress concept for base plates with longitudinal stiffeners welded on both sides cannot be applied economically in many cases. It should be noted here that the evaluation of the static test series, using the normative notch cases of DIN EN 1993-1-9 [1], guidelines of the International Institute of Welding [2] and prEN 1993-1-9 [3], is subject to a wide scatter across regulations. With regard to transverse stiffeners and cross joints, the influence of imperfections on the decisive structural stress is more significant. Nevertheless, the structural stress concept, based on the currently valid normative notch classifications, can be used economically. However, the evaluation of the fatigue tests on cross joints tends towards an overestimated notch drop in the structural stress concept. It can also be established that straight pull effects lead to reduced stress ranges in fatigue tests. These effects have not yet been taken into account in the standards. Consequently, the general applicability of the structural stress concept must be critically scrutinised in some points. This research report sets out extended regulations for the professional application of the structural stress concept. The objective of the research project was thus achieved. Publication: June 2022 Authors: Sc. N. Rausch, Prof. Dr.-Ing. M. Mensinger