Smart Semi-finished Parts for the Application in Sheet-Metal Structures

  • R. Neugebauer
  • L. Lachmann
  • W.-G. Drossel
  • M. Nestler
  • S. Hensel
Conference paper


In many fields of industry, e.g. automotive industry, light-weight concepts are gaining in importance. The background is an increasing shortage of natural resources combined with increasing requirements for comfort and safety. Through the use of light-weight concepts the efficiency of automotive vehicles and the driving dynamics are improved. Because the car body has amounts to 30% of total weight, it offers high potential for weight reduction. An increasing strength of sheet metal materials allows the reduction of thickness of auto body parts. Using the same materials this reduction leads to a decrease of structural stiffness. Adaptronic devices can be used to influence the stiffness locally. Sensors and actuators, e.g. based on piezoceramics, allow the detection and the reduction of unwanted vibrations. The state of the art application of piezomodules like Macro-Fibre-Composites (MFC) is performed with significant manual work. For high-volume production a new process chain has to be used. The paper presents a method which allows the application of piezomodules on 3D-formed parts. The application takes place before the forming operation. The encapsulation of the piezomodule is performed in different ways. In addition to a double layered sheet metal-composite a local applied sheet metal or plastic film can be used. The presented method offers good protection of the piezomodule against mechanical and chemical influences like splash water and dirt on the automotive parts. The local application method leads to a significant weight reduction.


Sheet Metal Friction Model Fibre Direction Aluminium Sheet Cover Layer 
These keywords were added by machine and not by the authors. This process is experimental and the keywords may be updated as the learning algorithm improves.



This Paper is based on the work within the Transregional Collaborative Research Centre 39 PT-PIESA” “Production Technologies for light metal and fibre reinforced composite based components with integrated PIEzoceramic Sensors and Actuators”, which is funded by the German Research Foundation (Deutsche Forschungsgemeinschaft) DFG. The authors gratefully acknowledge the support of the DFG.


  1. 1.
  2. 2.
    Drossel WG, Hensel S, Kranz B, Nestler M, Göschel A (2009) Sheet metal forming of piezoceramic-metal-laminar structures – Simulation and experimental analysis. In: CIRP Annals 2009 – Manufacturing Technology, pp 279–282Google Scholar
  3. 3.
    DIN EN 1465: Adhesives – Determination of tensile lap-shear strength of bonded assemblies, 2009Google Scholar
  4. 4.
    DIN EN 1464: Adhesives – Determination of peel resistance of adhesive bonds – Floating roller method, 2009Google Scholar
  5. 5.
    Neugebauer R, Lachmann L, Drossel WG, Nestler M, Hensel S (2010) Multi-layer compounds with integrated actor-sensor-functionality. In: Production Engineering, Special Issue, pp 379–384Google Scholar
  6. 6.
    Livermore Software Technology Corporation (LSTC) (2007) LS-DYNA® Keyword User’s Manual Version 971Google Scholar
  7. 7.
    Neugebauer R, Drossel WG, Lachmann L, Hensel S, Nestler M (2010) Experimental and numerical study on efficient forming operations of sheet-metal-compounds with integrated piezo-modules. In: Steel research international 81, No.13, pp 725–728Google Scholar
  8. 8.
    Drossel WG, Hensel S, Kranz B (2010) Simulation models for design and production of active structural parts with deformed piezoceramic-metal compounds. In: Society of Photo-Optical Instrumentation Engineers -SPIE-, Bellingham/Wash.: Behavior and Mechanics of Multifunctional Materials and Composites, San Diego, California, United States, Bellingham, WA: SPIE, Paper 764428 (Proceedings of SPIE 7644)Google Scholar
  9. 9.
    Neugebauer R, Kreißig R, Lachmann L, Nestler M, Hensel S, Flössel M (2009) Piezo-module-compounds in metal forming – experimental and numerical study. In: Brezina, T.: Recent advances in mechatronics, Berlin: Springer, pp 257–262Google Scholar

Copyright information

© Springer-Verlag Berlin Heidelberg 2013

Authors and Affiliations

  • R. Neugebauer
    • 1
  • L. Lachmann
    • 1
  • W.-G. Drossel
    • 1
  • M. Nestler
    • S. Hensel
      • 1
    1. 1.Fraunhofer Institute Machine Tools and Forming Technology IWUTU ChemnitzChemnitz/DresdenGermany

    Personalised recommendations