Simulationsbasierte Lebensdauervorhersage für Werkzeuge der Kaltmassivumformung [thesis]

Bernd Falk, Klaus Feldmann, Manfred Geiger
The prediction of tool life and reliability at an early stage in the development phase is an essential prerequisite for the correct dimensioning of the tool system and the evaluation of optimization measures. The previously known possibilities of failure simulation were limited in principle to the localization of the tool areas critical to failure and to the estimation of the average tool life. The task and subject of the present research work was to extend the tool life prediction by the
more » ... iction by the specification of the statistical distribution of the failure probability. The forecasting of such attributed service life data forms the basis for lower, and at the same time foreseeable and therefore predictable machine downtimes. Furthermore, higher service life values lead to a reduction of the tool cost share in the production costs. A suitable planning tool for the simulation-based tool life prediction is the concept of the comparison of the actual tool stress and it's stress resistance. It is a deterministic-probabilistic approach that combines the numerical simulation of the forming process, the modeling of specific failure mechanisms and statistical methods such as interference analysis. The statistical methods make it possible to measure the uncertainties and the spread of the primary process influencing variables, which ultimately represent the cause of the pronounced spread of the service life. In order to apply an approach of this kind to real problems, a number of prerequisites had to be met. Initially, these were statistically verified parameters to describe the fatigue behavior of the respective tool material. Furthermore, on the basis of the fatigue parameters, damage concepts had to be further developed or damage concepts already available had to be checked with regard to their performance and universal applicability for the service life calculation. Irrespective of the selected damage concept and the fatigue parameters used in this context, reliable data for quantifying the tool stress ultimately form the basis [...]
doi:10.25593/3-87525-136-9 fatcat:tkz5ksjdkrahzi2baayem4wkee