Metallic lightweight construction materials are used, for example, to increase efficiency and reduce emissions in many areas of the aerospace industry. Various welding, soldering, adhesive or screw connections are used to join the components. Flow drilling in combination with subsequent thread production for metallic lightweight profiles offers the possibility of producing an internal thread with a greater usable thread depth by locally expanding the material. Compared to conventional joining methods, the introduction of threads at the front end also offers significant potential for increasing efficiency in industrial production.
Within the framework of this research project, the status of the flow drilling process developed so far for the aluminium and magnesium alloys AlSi10Mg and AZ91 is to be extended with regard to technological and economic aspects. Related challenges, especially in the machining of the magnesium alloy AZ91, are to be overcome by the preceding insertion of a conventionally produced pilot hole. This is followed by the flow forming process, which produces the core bore necessary for thread forming. In contrast to thread machining, this process offers the advantage that the forming process results in work hardening of the material in the edge zone of the bore. On the basis of research results already obtained, the front-face flow drilling process is further being developed with regard to innovative tool concepts and other optimisation approaches. Selected process parameters, such as the initial tool temperature or the tool coating, are varied within the scope of the experimental investigations and evaluated comparatively with the help of the mechanical characterisation methods to be carried out by the Department of Materials Testing Technology. Due to the iterative character of the research project, the results are validated in this way. By transferring the results to industrial production, a resource-saving and efficient processing should be possible.
The research project aims at the holistic further development and characterisation of the face side flow drilling with subsequent threading of aluminium and magnesium alloys. In addition to further optimisation of the machining strategy, which will be advanced by means of the findings from practical tests, technological challenges are to be overcome by applying different tool concepts. The process-related geometric or microstructural properties of the internal threads are related to the mechanical properties, resulting in a structure-based analysis of the damage mechanisms, the understanding of which is absolutely necessary for the design of optimal process conditions.
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Arrival by Deutsche Bahn to Dortmund or Bochum central station.
From Dortmund central station, take the S1 city train in the direction of Düsseldorf to the "Dortmund Universität" station (7 minutes journey time).
From Bochum central station, take the S1 city train in the direction of Dortmund to the "Dortmund Universität" station (14 minutes journey time).
The city train runs regularly every 20 minutes in both directions. From the city train station, take the Skytrain (S-Universität stop) to the Campus Süd stop (1 stop, runs every 10 minutes).
From Dortmund Airport
By taxi to TU Dortmund University, Campus South (approx. 20 min and 30 €, see Map)
From Düsseldorf Airport
Take the city train S1 in the direction of Dortmund to the "Dortmund-Universität" station (approx. 60 min). From here, take the Skytrain in the direction of Campus South or Eichlinghofen (runs every 10 minutes and takes approx. 3 min.).
The H-Bahn is one of the hallmarks of TU Dortmund University. There are two stations on North Campus. One (“Dortmund Universität S”) is directly located at the suburban train stop, which connects the university directly with the city of Dortmund and the rest of the Ruhr Area. Also from this station, there are connections to the “Technologiepark” and (via South Campus) Eichlinghofen. The other station is located at the dining hall at North Campus and offers a direct connection to South Campus every five minutes.
The facilities of TU Dortmund University are spread over two campuses, the larger Campus North and the smaller Campus South. Additionally, some areas of the university are located in the adjacent “Technologiepark”.