Achivements

In earlier studies it was shown that forming of a compound with highly brittle piezoceramic fibers is possible. Therefore during the forming process a relative movement between piezomodule and the sheet metals is ensured using a viscous adhesive.  

With variation of the sandwich design, compounds with local and global cover sheets were produced. Bending test, deep drawing test and stretch drawing test were carried out to investigate several load cases for the piezomodule. Through various test methods (X-Ray, capacity test, investigation of the sensor and actuator functionality) the forming limits were identified and the functionality of the piezo-metal-compounds was characterized. In addition to the experiments numerical simulations of the forming processes were performed. Focus of the simulation is the description of the piezomodule loads resulting from the forming process and the prediction of the piezomodule functionality using a developed degradation model.

In order to show the potentials of the process chain, exemplary structural parts for active vibration control and health-monitoring were developed.

In collaboration with the subprojects A02 and A03 forming tests of micro-structured piezo-metal- compounds were realized. Additionally numerical studies for micro-structuring, joining by forming and deep-drawing of micro-structured piezo-metal-compounds were performed in close connection to experimental tests.

Figure 1: Rectangular cup with global and local cover sheet

Figure 2: Deep-drawing tool for fabrication of rectangular cups

Figure 3: Simulation model for forming of piezo-metal- compounds

Figure 4: Microsection of a bending sample with a bending radius of 10 mm

Figure 5: Functional demonstrator for the monitoring of a bolted joint (health-monitoring) using integrated piezomodules

Figure 6: Forming and simulation of micro-structured piezo-metal-compounds (cooperation with TP A02/A03)