Doctoral Researcher (m/f/d) – Intelligent optimization of a recycling-based hybrid injection moulding process

We are looking for a doctoral researcher (m/f/d) to join the research group “Processes” at the 伟德国际_伟德国际1946$娱乐app游戏 of Augsburg.

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The RG ‘Processes’ is investigating in innovative methods for manufacturing hybrid composites and material composites. The development of new, efficient manufacturing processes is aimed at maximizing the potential of these materials despite their higher costs. The focus is on serial and recyclable processes such as duromer- and thermoplastic-based injection moulding. In addition, combinations with generative manufacturing processes or metallic inserts are being investigated to further optimize material utilization. The processes are monitored online by adapted sensor technology.

Your research includes the development of a combined in-situ process based on forming of non-woven fabrics and injection co-moulding to produce high-quality components from recycled fibre materials. Furthermore, the process parameters are to be optimized in order to increase the quality and reproducibility of the components, especially in the case of fluctuating material properties. This work supports the development of AI-based systems in a Bavarian research project in collaboration with industrial companies.

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If you are interested in joining our team, please feel free to contact us by phone or email.

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Doctoral Researcher (m/f/d) – Predictive Maintenance in Gear Monitoring

For the research group “Condition Monitoring” at the research and teaching unit "Mechanical Engineering" at the 伟德国际_伟德国际1946$娱乐app游戏 of Augsburg, we are looking for a doctoral researcher (m/f/d).

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Gear wear reduces remaining useful life and can lead to serious system failures. Therefore, it is essential to record gear wear when applying predictive maintenance. This makes maintenance more efficient and saves time, costs and resources. When monitoring gears, machine learning enables rapid and precise analysis of sensor data to detect conditions or deviations that indicate impending failures.

Your research should enable the development of new concepts for monitoring gearboxes. Our research primarily includes the creation and use of sensor data for gear monitoring. The aim is to expand the application to real application scenarios together with industrial partners. A gearbox test bench is used to demonstrate the technology. To do this, you will set up a test stand for non-destructive testing of a gearbox demonstrator. With the help of software solutions, the measurement data can be evaluated and errors or anomalies can be detected early.

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If you are interested in joining our team, please contact us by phone or email.

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Doctoral Researcher (m/w/d) – Optimization of high-pressure die casting processes

We are looking for a doctoral researcher (m/f/d) to join the team at the assistant professorship “Data-driven Materials Processing” at the 伟德国际_伟德国际1946$娱乐app游戏 of Augsburg.

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Process optimization is a key part of sustainable production processes. Classical process simulation is usually good at predicting the properties of the components that are produced, given a certain set of production parameters. But what if the parameters aren't the right ones? You have to adjust the process parameters until you get the desired component properties. This leads to solving an inverse problem by using optimization. Our team specializes in setting up and validating process models with simulations and machine learning methods to optimize production processes. Your research involves an interdisciplinary mix of machine learning, physical simulation and experiments to optimize die casting processes. These activities are embedded in the AI Production Network Augsburg. Do you have an engineering degree, experience with production technology, and experience with programming?

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If you are interested to join as a doctoral candidate, please send a brief letter of motivation to the respective contact person.

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Doctoral Researcher (m/f/d) – Model-based non-destructive testing of foundry cores

We are looking for a Doctoral Researcher (m/f/d) – Model-based non-destructive testing of foundry cores to join the team at the assistant Professorship Data-driven Materials processing at the 伟德国际_伟德国际1946$娱乐app游戏 of Augsburg.

Sand cores are used in foundry technology to form non-removable geometries. In large-scale production, cores are increasingly produced with innovative inorganic substances due to lower environmentally harmful emissions. At present, however, there is still no process suitable for series production to detect and localize defects in the cores.

Your research mainly involves combining virtual models and experimental data. To this end, you will set up a test stand for non-destructive testing of the sand cores. With the help of a simulation model, the measurement data can be evaluated and defects in the core can be localized.

If you are interested in joining our team, please contact us by phone or email.

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AI-based Gear Condition Monitoring – Predictive Maintenance

The aim of the thesis is to analyze gearbox failures with a focus on monitoring anomalies resulting from various types of failures. An innovative AI-based approach will be developed to link sensor-based data with specific failure types. By combining modern data processing techniques with machine learning methods, the goal is to achieve precise identification and classification of anomalies, thereby improving the reliability and efficiency of gearboxes in a sustainable manner.

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More information can be found in the hyperlinked pdf:

AI-based Gear Condition Monitoring – Predictive Maintenance

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Robot Simulation for interaction with deformable bodies in an Industrial assembly

Traditional robotic assemblies rely on position-based control, which lacks the adaptability of human operators who can make fine adjustments based on tactile feedback. Integrating force and torque data into the robot control feedback loop offers significant advantages, particularly for leveraging advanced AI-based control. Extensive force and torque data are required to train AI-based robotic control efficiently. Generating this data through simulation optimises time and resources. This thesis aims to develop a generalised pipeline for generating synthetic force and torque data, focusing on an industrial assembly use case. The scenario involves interactions with deformable bodies, simulating real-world robot operations.

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More information can be found in the hyperlinked pdf:

Robot Simulation for interaction with deformable bodies in an Industrial assembly

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Coupling FEM simulation to robot simulations for contact-rich assembly tasks

Robot simulation software helps replicate robotic behaviour, enabling data augmentation and preempting unsafe collision paths without additional resource expenditure. However, these tools fall short in accurately modelling the mechanical behaviour of objects in the environment compared to traditional FEM software. This thesis aims to bridge this gap by integrating robot simulation with FEM-based modelling. The goal is to achieve realistic, dynamic mechanical behaviour of target objects in contact-rich assembly tasks, enabling more accurate and practical robotic simulations.

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More information can be found in the hyperlinked pdf:

Coupling FEM simulation to robot simulations for contact-rich assembly tasks

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Design for Recycling: Manufacturing and mechanical characterization of fiber-metal-laminates with activable interfaces

The study aims to optimize the design and fabrication of carbon fiber reinforced (CFRP) epoxy-based – aluminium laminates featuring a thermoplastic interlayer. Two manufacturing routes are considered. Firstly, an in-situ manufacturing is carried? out, combining the three different materials via hot-pressing. Secondly, an ex-situ approach aims to consolidate the prepreg material in a first step and combine it with aluminium and thermoplastic foil subsequently. The effects of the?? adapted design and fabrication on the mechanical performance are investigated by digital image correlation and acoustic emission measurements integrated in edge shear testing.

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More information can be found in the hyperlinked pdf:

Design for Recycling: Manufacturing and mechanical characterization of fiber-metal-laminates with activable interfaces

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Investigation of the Rheological Properties of Thermoplastics using Laser-Structured Shear Plates

The main goal of this work is to investigate how different surface structuring of the shear plate affects the rheological properties of a thermoplastic. A comparison of the viscosity and viscoelastic properties of the polymer with and without? structuring will be examined. Additionally, the change in rheological parameters will be analyzed based on shear and frequency dependence. The insights gained are intended to contribute to the optimization of the manufacturing process and the? improvement of the mechanical properties of the sandwich composites.

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More information can be found in the hyperlinked pdf:

Investigation of the Rheological Properties of Thermoplastics using Laser-Structured Shear Plates

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Experimental Studies on Acoustic Emission Sensor Verification

This master's thesis project aims to investigate the feasibility of predicting the calibration responses of AE sensors using a simpler setup involving a Laser Doppler Vibrometer. The goal is to create a predictive model that can assess the quality of sensors based on a more accessible and cost-effective verification procedure.

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More information can be found in the hyperlinked pdf:

Experimental Studies on Acoustic Emission Sensor Verification

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Designing and developing a smart sensor for process and condition monitoring

For real-time monitoring, which is a central topic in the working group “condition monitoring” and is already being implemented through the use of ultrasonic sensor, a smart sensor is now to be developed. For this purpose, this work aims to form a basis by enhancing a commercially available sensor of lower frequency with a microcontroller / single-board computer in such way, that it is able to collect, process and forward the data to a central computer via a suitable communication interface. The comparison of the developed sensor with a corresponding commercial system should round off the work.

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More information can be found in the hyperlinked pdf:

Designing and developing a smart sensor for process and condition monitoring

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Recycling of silicate foundry sands and binders

This thesis aims at developing a process that takes advantage of the solubility of the sodium silicate binder to wash it at elevated temperatures after the casting process, using only water without additional chemicals. The washing process? produces wastewater containing dissolved foundry binder and other impurities. The second goal is to recycle this water so it can be processed into a binder and does not have to be disposed of, thereby closing the material cycle for both binder? and sand.

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More information can be found in the hyperlinked pdf:

Recycling of silicate foundry sands and binders

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Development of a glass mold for observing molten metal

This thesis aims at developing a test mold that allows the mold filling to be observed through glass panels. This is recorded by? cameras and used to validate foundry simulations. Therefore, the most challenging casting geometries possible are? to be implemented, which push the existing simulation models to their limits.

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More information can be found in the hyperlinked pdf:

Development of a glass mold for observing molten metal

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Simulation of Friction Stir Welding

The aim of the work is to set up a finite element model in Abaqus that calculates the temperature and the formation of residual stresses during friction stir welding.

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More information can be found in the hyperlinked pdf:

Simulation of Friction Stir Welding

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Design for Recycling: Manufacturing and mechanical characterization of fiber-metal-laminates with activable interfaces

The study aims to optimize the design and fabrication of carbon fiber reinforced (CFRP) epoxy-based – aluminium laminates featuring a thermoplastic interlayer. Two manufacturing routes are considered. Firstly, an in-situ manufacturing is carried? out, combining the three different materials via hot-pressing. Secondly, an ex-situ approach aims to consolidate the prepreg material in a first step and combine it with aluminium and thermoplastic foil subsequently. The effects of the?? adapted design and fabrication on the mechanical performance are investigated by digital image correlation and acoustic emission measurements integrated in edge shear testing.

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More information can be found in the hyperlinked pdf:

Design for Recycling: Manufacturing and mechanical characterization of fiber-metal-laminates with activable interfaces

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Investigation of the Rheological Properties of Thermoplastics using Laser-Structured Shear Plates

The main goal of this work is to investigate how different surface structuring of the shear plate affects the rheological properties of a thermoplastic. A comparison of the viscosity and viscoelastic properties of the polymer with and without? structuring will be examined. Additionally, the change in rheological parameters will be analyzed based on shear and frequency dependence. The insights gained are intended to contribute to the optimization of the manufacturing process and the? improvement of the mechanical properties of the sandwich composites.

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More information can be found in the hyperlinked pdf:

Investigation of the Rheological Properties of Thermoplastics using Laser-Structured Shear Plates

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Fabrication, analysis and characterization of metal-polymer filaments for FDM 3D printing

The objective is to use additive manufacturing to find a high-performance alternative to SMC coil cores in electric motors. To this end, a thermoplastic that meets the requirements must be found. This will then be used to? produce the ferrite thermoplastic filament, which will subsequently be characterized and tested for its process suitability.

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More information can be found in the hyperlinked pdf:

Fabrication, analysis and characterization of metal-polymer filaments for FDM 3D printing

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Recycling of silicate foundry sands and binders

This thesis aims at developing a process that takes advantage of the solubility of the sodium silicate binder to wash it at elevated temperatures after the casting process, using only water without additional chemicals. The washing process? produces wastewater containing dissolved foundry binder and other impurities. The second goal is to recycle this water so it can be processed into a binder and does not have to be disposed of, thereby closing the material cycle for both binder? and sand.

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More information can be found in the hyperlinked pdf:

Recycling of silicate foundry sands and binders

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Development of a glass mold for observing molten metal

This thesis aims at developing a test mold that allows the mold filling to be observed through glass panels. This is recorded by? cameras and used to validate foundry simulations. Therefore, the most challenging casting geometries possible are? to be implemented, which push the existing simulation models to their limits.

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More information can be found in the hyperlinked pdf:

Development of a glass mold for observing molten metal

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Simulation of Friction Stir Welding

The aim of the work is to set up a finite element model in Abaqus that calculates the temperature and the formation of residual stresses during friction stir welding.

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More information can be found in the hyperlinked pdf:

Simulation of Friction Stir Welding

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Economic assistant job for start-up project "sensAI"

In the sensAI research project, a concept for non-destructive material characterization is being developed and tested. This system is intended to play a key role in quality assurance in the processing of recycled plastics. We are looking for economic assistants for this project. In the area of business administration, we need support with market and competition studies, among other things. This will be used to develop strategies for market entry, marketing and other business management topics.

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More information can be found in the hyperlinked pdf:

Economic assistant job for start-up project "sensAI"

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