Numerisch-simulative Modellbildung für die Entwicklung von Technologien zur Herstellung von Piezo-Metall-Verbunden und deren Charakterisierung

Piezoceramic-metal-compounds use a metallic load transmitting layer, a cover sheet and an integrated piezoceramic fibre module to extent the functionality of structural parts for adaptronic applications. The piezoceramic module is deformed by the surrounding metallic sheets during the part production. Within the process, a lubricated floating bearing, implemented by usage of a liquid adhesive, reduces the module stresses drastically to a non-critical level compared with the case of a completely tied module. The adhesive fully cures after the shaping operation is performed and thus secures a stiff joint between the piezoceramic fibre module and the surrounding sheet metals. Despite the lubricated floating bearing, shaping of the sheet metals may cause geometric constraints, which induce significant membrane strains in the fibre module. This possible one-off overload during the production process can cause a reduction of the functionality of piezoceramicmetal-compounds. In this thesis a method is developed that can be used to determine the functionality reduction of piezoceramic-metal-compounds and utilises the results in numerical simulations to predict the residual performance of such structural parts. The decrease of the piezoceramic module performance dependent on load level and direction is investigated with basic experiments. With the results a performance model is derieved. It is further validated by the comparison of simulations and experimental results of the compound shaping operation. The thesis focuses on the development of a methodology, that allows for a prediction of the adaptronic part functionality after shaping operation. As a result, within the early product and process chain design stage, a tool is available to evaluate the effeciency of the process