The transformation of metastable austenite to martensite under mechanical loading can be harnessed to create a material sensor which records a measure of the load history without the need for electrical energy and can be read out at arbitrary intervals via eddy current probing, thus leading to an ultra-low-power sensing solution. This paper presents possibilities of processing this load amplitude-dependent evolution of martensite content loading for component fatigue analysis. The general method is based on using a theoretical material model typically used in finite element analyses which includes hardening plasticity and phase transformation to precompute tables of stress amplitude or cumulative damage corresponding to different sensor readings which can be stored on a low power processing system onboard the component for energy-efficient lookup. At nominal single amplitude loading, the sensor can be used as a load cycle counter for known loads or as an overload detection device upon divergent martensite content rise. Interpretation of block program loading is less practical due to resolution issues. Under random loading, sequence effects get averaged out; interpretation is easiest with narrow load spectra, but information can be gained from very wide spectra as well. Multiple sensors at different locations can aid interpretation. Uncertainty due to necessary assumptions and untreated influences of temperature and loading rate is discussed.

AbstractThis contribution summarizes the current state of research regarding so‐called sensor‐integrating machine elements as an enabler of digitalization in mechanical engineering and——if available—their application in industry. The focus is on the methodical aspects of the development of these machine elements in general as well as specific sensor‐integrating machine elements that are either already in use or currently under development. Developmental aspects include the robust design of initially evaluated concepts for sensor‐integrating machine elements as well as their modularization. Smart materials with sensory functions are included in the analysis as well as the differentiation with regard to add‐on sensors. The aim of the authors interlinked by a special research program funded by the German Research Foundation (DFG) is to facilitate the exchange with other researchers with the help of the comprehensive overview given in this contribution. The contribution concludes with a brief discussion of open challenges, such as the energy supply and data transfer in rotating systems and also data security.

Frictional shaft-hub connections are often used in drive train applications. The classic version is fitted by a temperature difference between the cold shaft and the hot hub, or simply axial press-fitted at room temperature. The critical point in this type of connection is the contact pressure at the edge of the hub regarding the relative deformation between the shaft and the hub under dynamic operating loads. Another innovative version, the internal press-fit, leads to a tolerance insensitive lightweight design using a tube as shaft and a controlled plastic deformation by internal high pressure. The internal press-fit connection is a special research topic at the IMW, TU Clausthal. The use of internal high pressure allows to trigger the contact pressure at the edge of the hub on an optimum value. The product of contact pressure and slipway is the key value to determine the fatigue resistance and load capacity of this kind of connection. /1/ and /2/ defined a critical range of slipway amplitudes between 5 and 25 pm for fretting. The normal use and main function of a shaft-hub connection is the transmission of torque. Regarding the different torsional stiffness of the shaft and the hub, there will be a difference in deformation in the contact zone between the shaft and the hub, which is necessary to measure on a probe under oscillating torque load. The measurement on the test-rig in /3/ was done with a POLYTEC torsional LDV (controller OFV-4000, sensor head OFV-400). In general the continuously oscillating torque load allowed a serial measurement of the torsional movement of the shaft and the hub. The difference of the two maximum values is the expected slipway between the two parts in the critical zone at the edge of the hub. The main benefits of the Torsional LDV in this application are the very small measuring point (next to the contact), no influence on the probe, no special preparation of the probe and a really good resolution. The paper gives an overview to the technical background of the measured value, to the measuring setup, to the other used measuring techniques and to the measuring results.

Purpose – This work aims to investigate the direct production of electrical discharge machining (EDM) electrodes by means of the selective laser sintering (SLS) technique using a new non-conventional metal-matrix composite material (TiB2-CuNi). The influence and optimization of the main SLS parameters on the densification behavior and porosity is experimentally studied. EDM experiments are also performed to evaluate the electrodes performance. Design/methodology/approach – The new EDM electrode material used was a powder system composed of TiB2 and CuNi. Making use of a designed systematic experimental methodology, the effects of layer thickness, laser scan speed and scan line spacing were optimized, where aspects such as densification behavior, porosity and surface morphology of the samples were analyzed through microstructural and surface analysis. EDM experiments were conducted under three different regimes in order to observe the electrodes behavior and performance. The results were compared with copper powder electrodes manufactured by SLS and EDMachined under the same conditions. Findings – The experimental results showed that the direct SLS manufacturing of composite electrodes is feasible and promising. The laser scan speed has a high effect on the densification behavior of the samples, while the effect of scan line spacing on the porosity is more visible when the overlapping degree is considered. Surface morphology was not affected by the scan line spacing, whereas balling phenomenon was reported, regardless of the scan line spacing. The EDM results showed that the TiB2-CuNi electrodes had a much superior performance than the copper powder electrodes made by SLS, regardless of the EDM regime applied. Research limitations/implications – Generally, the machine tool itself promotes some restrictions to the SLS process optimization. It is normally attributed to the characteristics of the laser type and the amount of energy that can be delivered to the powder bed. The present investigation could not cover all the optimization potential involved with the studied material due to limitations of the SLS machine tool used. Originality/value – Significant results on the direct SLS manufacturing of a new non-conventional composite material, which has a great technological potential to be used as an EDM electrode material, are presented. Valuable guidelines are given in regard to the SLS optimization of TiB2-CuNi material and its performance as an EDM electrode. This work also provides a systematic methodology designed to be applied to the SLS process to produce EDM electrodes.

Electrical discharge machining (EDM) is a nonconventional machining process widely applied for the manufacture of intricate shapes in hard materials which are not easily machined by conventional machining processes. The production of geometrically complex EDM electrodes is difficult, time consuming, and it can account for about 50 % of the total process costs. Selective laser sintering (SLS) can be an alternative technique to produce EDM electrodes in a faster way. This work conducted an experimental study on the performance of EDM electrodes made by SLS using pure copper, bronze–nickel alloy, copper/bronze–nickel alloy, and steel alloy powders. Important EDM performance measures such as material removal rate and volumetric relative wear were investigated and discussed for finishing, semifinish, and roughing regimes. This work contributes with an insight into the production of EDM electrodes via selective laser sintering, as an alternative technique to conventional machining processes, as well as to evaluate the performance of the electrodes, and also provide directions for future research on this field.

It is generally observed that cracks initiate at the stick-slip (partial slip) zone between fretting contact interface and lead to fretting fatigue. In order to avoid unexpected fracture caused by fretting fatigue, it is worth to trace the evolution of stick-slip zone under alternating loading and find critical loadings of fretting fatigue. This paper will investigate the change of stick-slip boundary in teeth flank of spline shaft-hub connections (SHC) under different combinations of bending moment and fluctuating torque via FE simulation. The normalized parameters o-b, and are used to quantify the magnitude of bending moment and torque in order to eliminate the effects of specific spline SHC parameters in evaluation of different load effects. Results showed that the stick and stick-slip regions spread toward teeth root and the stick region disappeared under loading combination of smaller sigma(bn1/)tau(in1) ratio with the increase of tau(in1); The settled stick region disappeared when sigma(bn1)/tau(in1)=0.3-0.35, and it is more wear predominant when sigma(bn1)/tau(in1)>= 0.35.

Due to increased product requirements, usual conditions for materials cannot be applied anymore. To reduce energy consumption, lightweight constructions are demanded but they cannot stand necessary mechanical stress. Therefore, local reinforced elements are applied for instance. According to actual research in material sciences, it is prerequisite to verify the position of this strengthening. Various physical principles can be used for non-destructive testing of this effect. In this article, an approach based on acoustic signals is presented. On the one hand a strategy could be to do comparative studies between nominal and sample and on the other to predetermine the place just by acoustic parameters like eigenmodes. In preliminary test, vibration characteristics of these innovative materials (e.g. bake-hardening plate and sandwich structure) are determined and reveal capabilities for acoustic methodologies. So, this approach could be a promising tool to localize reinforced elements.

Design engineers can choose from a large variety of materials in order to fulfill a certain function. In those fields of application with a lower level of complexity, it is often sufficient to manufacture the entire component in a "monolithic" manner from one single material. Concurrent, partly contradictory and, most probably, local requirements that must be fulfilled by a component often make material selection more difficult. As a consequence, it is often necessary to use several different materials with a local and functional orientation, which is a part of the multi-material design strategy. The potential of different materials can be used most effectively if this information is made available to the design engineers as early on in the design process as possible. The aim of the SFB 675 sub-project C7, therefore, is the development of a systematic design approach (Finite Element Design, FED) that focuses on finite component elements. As a result, the potential of the optimization of local properties is taken into consideration, and the interaction between the materials, production processes, and design can all be described.