@article{63512, abstract = {{The state of the art shows that PBF-LB/M offers great potential for pressure-loaded parts, with significant weight reductions and simultaneous optimization of flow resistance. This study is aimed at applying existing calculation methods for pressure-loaded parts to additively manufactured pipe structures, considering the two materials EN AC-43000 (3.2381, AlSi10Mg) and AISI 316L (1.4404, X2CrNiMo17-12-2). For this purpose, systematic tensile tests are carried out for both materials. In addition, a statistical evaluation is performed to determine the design-relevant strength characteristics with a survival probability Ps of 97.5 % for both materials in the as-built and heat-treated condition. Pipe specimens are manufactured, half of which are heat treated, geometrically measured and then subjected to a burst pressure test to experimentally determine the failure-critical internal pressure. These results are compared with calculated burst pressures. The calculations are based on the application-relevant methods identified in this study, considering the strength values determined for the respective material condition. This comparison is used to assess the suitability of the calculation methods for additively manufactured pipe structures, based on the materials investigated.}}, author = {{Koers, Thorsten and Magyar, Balázs and Bödger, Christian and Tröster, Thomas}}, issn = {{0308-0161}}, journal = {{International Journal of Pressure Vessels and Piping}}, keywords = {{PBF-LB/M, Pipe structures, Strength assessment, Burst pressure test, Geometrical deviations}}, publisher = {{Elsevier BV}}, title = {{{Analytical and experimental determination of the failure-critical pressure of pipe structures manufactured by PBF-LB/M}}}, doi = {{10.1016/j.ijpvp.2026.105753}}, year = {{2026}}, } @inbook{59261, author = {{Magerkohl, Sebastian and Magyar, Balázs}}, booktitle = {{Innovative Produktentwicklung durch additive Fertigung}}, editor = {{Lachmayer, Roland and Oel, Marcus and Kaierle, Stefan}}, isbn = {{9783662693261}}, publisher = {{Springer Berlin Heidelberg}}, title = {{{The Role or Rule of the Development Methodology for Additive Manufacturing}}}, doi = {{10.1007/978-3-662-69327-8}}, year = {{2025}}, } @article{63495, abstract = {{Inhalt Der Leitfaden der Wissenschaftlichen Gesellschaft für Produktentwicklung (WiGeP) dient als umfassende Orientierung für die Gestaltung der universitären Lehre im Bereich der Produktentwicklung. Er wurde überarbeitet, um aktuellen gesellschaftlichen Herausforderungen wie dem Klimawandel, sinkenden Studierendenzahlen und abnehmenden technischen Vorkenntnissen zu begegnen. Ein zentrales Anliegen ist es, Ingenieurinnen und Ingenieure zu befähigen, aktiv zur Lösung globaler Probleme beizutragen. Didaktisch wird der Einsatz moderner Lehrmethoden wie Projektarbeit, Flipped-Classroom, digitale Tools, VR-Lernen sowie adäquater Prüfungsformate nach Taxonomiestufen empfohlen. Inhaltlich stehen Maschinenelemente, methodische und virtuelle Produktentwicklung im Fokus, ergänzt durch interdisziplinäre Themen wie Nachhaltigkeit, Digitalisierung und Technikethik. Zudem wird die Bedeutung technischer Bildung an allgemeinbildenden Schulen hervorgehoben, um die Studierfähigkeit und Begeisterung für Technik frühzeitig zu fördern. Der Leitfaden richtet sich an Lehrende an Hochschulen, Hochschuldidaktiker, Studiengangverantwortliche sowie bildungspolitische Entscheidungsträger und interessierte Akteure aus Gesellschaft und Industrie. Insgesamt versteht sich der Leitfaden als strategisches und operatives Werkzeug zur Weiterentwicklung der ingenieurwissenschaftlichen Lehre mit dem Ziel, exzellent ausgebildete und gesellschaftlich verantwortungsbewusste Produktentwicklerinnen und Produktentwickler für die Zukunft zu qualifizieren.}}, author = {{Bender, Beate and Husung, Stephan and Kirchner, Eckhard and Kletzin, Ulf and Kossack, Frederike and Lohrengel, Armin and Magyar, Balázs and Riedel, Oliver and Stahl, Karsten}}, issn = {{0720-5953}}, journal = {{Konstruktion}}, number = {{10}}, pages = {{54--65}}, publisher = {{VDI Fachmedien GmbH and Co. KG}}, title = {{{Universitäre Lehre in der Produktentwicklung/Academic teaching in product development}}}, doi = {{10.37544/0720-5953-2025-10-54}}, volume = {{77}}, year = {{2025}}, } @techreport{63209, abstract = {{Die DFG-Projekte AddFeRo-PM (406108415) und AddFeRo-SR (465089065) untersuchten die Potenziale des LB-PBF/M-Verfahrens zur Herstellung von Rotoren für unterschiedliche elektrische Maschinen. Im interdisziplinären Ansatz wurden Materialentwicklung und mechanische sowie elektromagnetische Optimierung verbunden. Im Projekt „AddFeRo-PM“ wurde der Rotor einer permanentmagneterregten Synchron- maschine (PMSM) untersucht. FeSi erwies sich als geeignete Legierung, konnte aber wegen Spannungsrissen nur bis zu 3 % Siliziumanteil (kurz: FeSi3) verarbeitet werden. Mechanische und elektromagnetische Untersuchungen ermöglichten eine 3D-Optimierung der Rotorgeometrie und -struktur. Der Demonstrator wurde additiv gefertigt und zeigt Leicht-baupotenziale sowie reduzierte Drehmomentwelligkeit. Im Folgeprojekt „AddFeRo-SR“ kam eine Hochtemperatur-Bauraumheizung (HTBH) zum Einsatz, die FeSi mit 6,5 % Siliziumanteil verarbeitbar machte, welches bessere elektro- magnetische Eigenschaften bietet. Sie wurde bei einer Synchron-Reluktanzmaschine (SynRM) getestet. Eine hybride Rotorfertigung erwies sich jedoch aufgrund von HTBH-Einschränkungen als ungeeignet, weshalb eine einteilige Fertigung mit FeSi3 umgesetzt wurde. Experimente bestätigten vergleichbare Betriebsergebnisse zur konventionellen Fertigung bei reduzierter Rotormasse. Zusätzlich wurde eine Methodik entwickelt, um additive Verfahren als Ergänzung zur konventionellen Fertigung zu integrieren. Beide Projekte zeigen das Potenzial additiver Fertigung für Leichtbau und Wirkungsgradsteigerung im Elektromaschinenbau und bieten wertvolle Grundlagen für industrielle Anwendungen.}}, author = {{Haase, Michael and Behrendt, Marius and Hengsbach, Florian and Kunnathully Sathees Kumar, Vinay and Magerkohl, Sebastian and Magyar, Balázs and Ponick, Bernd and Schaper, Mirko and Zimmer, Detmar}}, keywords = {{Additive Fertigung, Elektromotor, Leichtbau, Synchronmotor, DFG}}, publisher = {{Technische Informationsbibliothek}}, title = {{{Additive Fertigung im Elektromaschinenbau: Erforschung von Potentialen der additiven Fertigung in Rotoren permanentmagneterregter Synchronmaschinen}}}, doi = {{10.34657/26753}}, year = {{2025}}, } @article{52254, author = {{Bührmann, Tobias and Magyar, Balázs}}, isbn = {{978-3-381-10091-0}}, journal = {{Tribologie und Schmierungstechnik}}, number = {{6/23}}, pages = {{34--42}}, title = {{{Approximate simulation of the hysteresis friction of radial shaft seals}}}, doi = {{10.24053/TuS-2023-0038}}, volume = {{70. Jahrgang}}, year = {{2024}}, } @inproceedings{48095, abstract = {{Fused deposition modeling (FDM) is an additive manufacturing process that can be used to manufacture three-dimensional thermoplastic components layer by layer. One disadvantage of FDM is the shrinkage of the components during the manufacturing process. The filament is molten in the nozzle, deposited layer by layer, and cools down again. During solidification, the filament shrinks inhomogeneously in the x/y/z direction, which leads to distortion of the component geometries. Particularly with higher nominal lengths and complex local geometries, there is a need for optimization with regard to dimensional accuracy. The aim of this paper is to counteract this on the software side with global as well as local shrinkage factors. The expected shrinkage within a layer is predicted with an in-house developed software. The geometric accuracy of the model is verified by experimental investigations on cylindrical test specimens. In these, the so-called clover effect occurs as a result of the shrinkage. The circular shape of the deposited layer is deformed by the distortion in the x–y plane comparable to a clover. Finally, the results are validated by analyzing a demonstrator in the form of a bracket.}}, author = {{Koers, Thorsten and Magyar, Balázs}}, booktitle = {{Macromolecular Symposia}}, editor = {{Lamanna, Giuseppe and Opran, Constantin}}, location = {{Bucharest, Romania}}, number = {{1}}, publisher = {{Wiley}}, title = {{{Compensation of the Shrinkage Behavior Occurring in Cylindrical Components in the FDM Process}}}, doi = {{https://doi.org/10.1002/masy.202200185}}, volume = {{411}}, year = {{2023}}, } @inproceedings{49781, author = {{Magerkohl, Sebastian and Haase, Michael and Magyar, Balázs}}, location = {{Schweinfurt}}, title = {{{Future of electric motors: Additive manufacturing of components with innovative lightweight and cooling structures}}}, year = {{2023}}, } @inproceedings{50076, author = {{Bührmann, Tobias and Magyar, Balázs}}, booktitle = {{64. Tribologie-Fachtagung 2023}}, location = {{Göttingen}}, title = {{{Approximate simulation of the hysteresis friction of radial shaft seals}}}, year = {{2023}}, } @inproceedings{49555, author = {{Rauhaus, Johann and Schadomsky, Magnus and Magyar, Balázs and Zimmer, Detmar}}, booktitle = {{Tagungsband der 64. Tribologie-Fachtagung}}, isbn = {{978-3-9817451-8-4}}, location = {{Göttingen}}, title = {{{Untersuchung des Reibungs- und Deformationsverhaltens von schnelllaufenden Bremsen}}}, year = {{2023}}, } @inbook{52656, author = {{Thielen, Stefan and Antonyuk, Sergiy and Aurich, Jan C. and Beck, Tilmann and Hasse, Hans and Kopnarski, Michael and Magyar, Balázs and Sauer, Bernd and Smaga, Marek}}, booktitle = {{Component Surfaces}}, isbn = {{9783031355745}}, issn = {{1860-5168}}, publisher = {{Springer International Publishing}}, title = {{{Manufacturing-Morphology-Property Relationships for Rotating Shaft Sealing Systems}}}, doi = {{10.1007/978-3-031-35575-2_14}}, year = {{2023}}, } @article{52657, abstract = {{Lubricants play a central role in many technical applications, e.g. in bearings and gears as well as in machining processes. In such applications, lubricants are exposed to extreme conditions in the contact area. In lubrication gaps, the pressure can reach values up to 5 GPa. The thermophysical properties of lubricants, and in particular the viscosity, at such extreme conditions have an important influence on the friction and wear behavior of a tribosystem. Accordingly, reliable lubricant property models are a prerequisite for accurate tribological simulations, e.g. elastohydrodynamic lubrication (EHL) simulations. Presently, the vast majority of experimental thermophysical property data are only available up to 1 GPa. Thus, reliable and robust models with strong extrapolation capabilities to higher pressure are required. In this work, viscosity measurements of squalane in a temperature range be tween 20 °C and 100 °C and pressures up to 1 GPa were carried out. Based on that data, a physical model for the viscosity was developed. The model is built by combining a molecular-based equation of state with the so-called entropy scaling approach. Finally, we demonstrate how this fluid property model can be favorably integrated in an EHL simulation by an application programming interface (API). The novel hybrid modeling approach is promising for future applications.}}, author = {{Wingertszahn, Patrick and Schmitt, Sebastian and Thielen, Stefan and Oehler, Manuel and Magyar, Balázs and Koch, Oliver and Hasse, Hans and Stephan, Simon}}, issn = {{0724-3472}}, journal = {{Tribologie und Schmierungstechnik}}, keywords = {{Surfaces, Coatings and Films, Surfaces and Interfaces, Mechanical Engineering, Mechanics of Materials}}, number = {{4-5}}, pages = {{5--12}}, publisher = {{Narr Francke Attempto Verlag GmbH + Co. KG}}, title = {{{Measurement, Modelling, and Appli cation of Lubricant Properties at Extreme Pressures}}}, doi = {{10.24053/tus-2023-0017}}, volume = {{70}}, year = {{2023}}, } @inbook{45360, author = {{Haase, Michael and Bieber, Maximilian and Tasche, Frederik and Schaper, Mirko and Hoyer, Kay-Peter and Ponik, Bernd and Magyar, Balázs}}, booktitle = {{Proceedings of the 19th Rapid.Tech 3D Conference Erfurt, Germany, 9–11 May 2023}}, editor = {{Kynast, Michael and Eichmann, Michael and Witt, Gerd}}, isbn = {{978-3-446-47941-8}}, publisher = {{Carl Hanser Verlag GmbH & Co. KG}}, title = {{{Umsetzung einer optimierten Oberflächenschlitzung zur Wirbelstromverlustreduktion auf der Oberfläche eines additiv gefertigten Permanentmagnet-Rotors}}}, doi = {{https://doi.org/10.3139/9783446479425.001 }}, year = {{2023}}, } @inproceedings{47084, abstract = {{Fused Deposition Modeling (FDM) is an additive manufacturing process to produce complex thermoplastic geometries layer by layer. The filament is melted in a nozzle, iteratively deposited, and then cools down. Due to the solidification process, the deposited filament strands deviate from their intended position due to shrinkage, resulting in significant geometric deviations in the final part. In terms of dimensional accuracy, there is a need for optimization, especially for local curved geometries in relation to the global part with higher nominal dimensions. The aim of this study is to investigate the size and shape deviations for cylindrical FDM elements and to compensate the expected deformations by using an in-house software with adaptive scaling factors in the x-y plane. Previous studies mainly focus on simple, non-curved objects, this study also considers the influence of curvature and global as well as local deviations on the final part.}}, author = {{Koers, Thorsten and Magyar, Balázs}}, booktitle = {{Proceedings of the 34th Annual International Solid Freeform Fabrication Symposium 2023}}, editor = {{Beaman, Joseph}}, location = {{Austin, Texas, USA}}, title = {{{Determination and Compensation of the Shrinkage Behavior of Cylindrical Elements in the FDM Process}}}, doi = {{https://doi.org/10.26153/tsw/50920}}, volume = {{34}}, year = {{2023}}, } @inproceedings{48790, abstract = {{To ensure uniform documentation of support structure information, a concept is presented that enables a standardized depiction of support structures in technical drawings based on ISO 128-3. To this end, requirements for a uniform depiction are defined and a procedure for drawing entry is presented. The drawing entry should contain all production-relevant support structure information. The standardized documentation of support structure information in technical drawings is intended to ensure a simple, clear and safe exchange of information between business units or different companies along the value chain. As a result a possible drawing entry of support structures was developed. To distinguish between different support structure types, a standardized depiction of geometrical information in a specification field is shown. The specification field gives a detailed description of the support structure type, the geometry as well as the connection to the part and the building platform. Also uncommon support types like lattice structures or CAD based support structures can be implemented. To ensure the usability the depictio is editable and extendable.}}, author = {{Lammers, Stefan and Koers, Thorsten and Magyar, Balázs and Zimmer, Detmar and Lieneke, Tobias}}, booktitle = {{Proceedings of the 34th Annual International Solid Freeform Fabrication Symposium 2023}}, editor = {{Beaman, Joseph}}, location = {{Austin, Texas, USA}}, title = {{{Depiction of support structures in technical drawings}}}, doi = {{https://doi.org/10.26153/tsw/50982}}, volume = {{34}}, year = {{2023}}, } @article{34434, abstract = {{In timing chain drives, the chain is the critical component regarding the wear. Relative movements take place at the chain joint between pin and bush, which lead to wear of the chain joint due to friction and so to chain elongation. The chain joint is generally lubricated with oils, through which elastohydrodynamic processes can occur in the gap between the pin and the bush of the chain joint. A simulation model is developed here to examine these elastohydrodynamic processes considering a mass conserving cavitation model, the Newtonian flow behaviour of the lubricant and the structuring of the bush surface, whereby the real form of the bush is considered. MBS simulations are used to obtain realistic loads on the chain joint.}}, author = {{Simo Kamga, Lionel and Meffert, Dominik and Magyar, Balázs and Oehler, Manuel and Sauer, Bernd}}, issn = {{0301-679X}}, journal = {{Tribology International}}, keywords = {{EHL-simulation, Cavitation, Chain drives, Chain joint, Micro-structuring}}, pages = {{107564}}, title = {{{Simulative investigation of the influence of surface texturing on the elastohydrodynamic lubrication in chain joints}}}, doi = {{https://doi.org/10.1016/j.triboint.2022.107564}}, volume = {{171}}, year = {{2022}}, } @inproceedings{34431, abstract = {{In diesem Beitrag werden zuerst die Hauptanforderungen für Schmierstoffe für die E-Mobilität dargestellt. Anschließend wird erklärt, welche technische Herausforderungen aus den sehr unterschiedlichen Anforderungen der einzelnen Komponenten resultieren. Danach wird der Einfluss der Grundölsorte, der Viskosität und der Additivierung diskutiert. Zum Schluss werden die typischen Unverträglichkeiten der eingesetzten Materialien und die damit verbundenen Schadensarten bzw. die Tests zur frühzeitigen Aufklärung, vorgestellt.}}, author = {{Magyar, Balázs and Freise, Rainer}}, booktitle = {{Experten-Forum Powertrain: Reibung in Antrieb und Fahrzeug 2019}}, editor = {{Liebl, Johannes}}, isbn = {{978-3-658-28711-5}}, pages = {{78–88}}, publisher = {{Springer Fachmedien Wiesbaden}}, title = {{{Schmierstoffentwicklung für E-Antriebe: Der Teufel steckt im Detail}}}, doi = {{10.1007/978-3-658-28711-5_8}}, year = {{2020}}, } @article{34435, abstract = {{Radial shaft sealing rings (RSSR) are important machine elements used in rotating and oil lubricated systems. Their main task is to prevent oil from exiting the system and dirt particles from entering the system. When this function is not fulfilled, a leakage can occur and cause excessive damage after certain operating times, such as gear failure due to insufficient lubrication. This is the reason for the high level of current research interest in seals. The sealing function of RSSR occurs in the contact area between the sealing lip and the shaft. The contact takes place over a very small contact width of approximately 1 μm. These extremely small dimensions and the complex relationships between the functional influencing variables on the radial shaft sealing system make it difficult to simulate wear on the sealing ring. The energetic consideration of the wear process offers the possibility of quantifying influencing variables more easily by their energetic contribution, which can be determined experimentally. Based on experimentally measured total friction moments, and with the help of a semi-analytical (SA) solid contact model based on the half-space theory, this paper presents a modelling approach for the calculation of wear at the sealing ring. The model presented in this work differs from the existing models in two ways. The first particularity is the coupling of SA method with finite element method (FEM) for the resolution of the contact between the sealing lip and the shaft, allowing a fine discretization of the contact zone (by SA method) and the consideration of the structural behavior (by FE method). The SA method compared to the commonly used FEM presents a great saving in computation time. The second particularity is the use of the real data obtained during the wear tests. Most existing simulation models are based purely on contact pressure. This means that through the contact pressure obtained by simulation and a given sliding distance value, a friction energy will be estimated which will be used in a next step using a wear model such as Archad’s to calculate the wear rate. In this publication the value of friction energy was obtained directly on an experimental basis and a more appropriate wear law, such as Fleischer’s, taking into account the friction conditions, was used to estimate the wear rate.}}, author = {{Foko Foko, Flavien and Heimes, Julia and Magyar, Balázs and Sauer, Bernd}}, issn = {{2075-4442}}, journal = {{Lubricants}}, number = {{2}}, title = {{{Friction Energy-Based Wear Simulation for Radial Shaft Sealing Ring}}}, doi = {{10.3390/lubricants8020015}}, volume = {{8}}, year = {{2020}}, } @article{34436, abstract = {{Regarding the increasing demand in seal lifetime and energy efficiency, a detailed microscopic simulation is necessary—as an addition to experimental investigations—to better understand and improve radial shaft seals. For this purpose, typically thermoelastohydrodynamic lubrication (TEHL) simulations are used. The published models range from rather simple elastohydrodynamic lubrication (EHL) models to very sophisticated TEHL models. Only very few models take into account the roughness or microstructure of both contact surfaces, though, since this would require the consideration of transient effects. In this article, a transient TEHL model for the contact of radial shaft seals is presented. Studies of the sealing contact are conducted, and the possibility of investigating shaft microstructuring is shown.}}, author = {{Thielen, Stefan and Magyar, Balázs and Sauer, Bernd}}, issn = {{0742-4787}}, journal = {{Journal of Tribology}}, number = {{5}}, title = {{{Thermoelastohydrodynamic Lubrication Simulation of Radial Shaft Sealing Rings}}}, doi = {{10.1115/1.4045802}}, volume = {{142}}, year = {{2020}}, } @article{35193, author = {{Keßler, A and Elkenkamp, P and Magyar, Balázs and Mayer, C}}, issn = {{0724-3472}}, journal = {{Tribologie und Schmierungstechnik}}, number = {{2}}, pages = {{23--28}}, title = {{{Beurteilung der Leistungsfähigkeit von Schmierstoffen mittels eines FZG Prüfstandes}}}, volume = {{67}}, year = {{2020}}, } @article{34432, abstract = {{Diese Untersuchung befasst sich mit dem in der Praxis häufig auftretenden, riefenförmigen Verschleiß gehärteter Wellen im Dichtkontakt mit Radialwellendichtringen (RWDR) aus Fluorkautschuk (FKM). Ziel ist es, die Verschleißmechanismen an einer gehärteten Stahlwelle im geschmierten tribologischen Kontakt mit einem elastomeren FKM-Radialwellendichtring anhand experimenteller Modellsysteme aufzuklären. Weiterhin wird die Wechselwirkung des Dichtringverschleißes und Wellenverschleißes aufgrund der sich ständig verändernden Oberflächenmorphologie der Kontaktpartner oberflächenanalytisch charakterisiert. Das entstandene Schadensbild kann simulativ nachgestellt werden und zeigt eine gute Übereinstimmung mit dem tribologischen Experiment.}}, author = {{Burkhart, Christoph and Emrich, Stefan and Magyar, Balázs and Kopnarski, Michael and Sauer, Bernd}}, issn = {{0724-3472}}, journal = {{Tribologie und Schmierungstechnik}}, keywords = {{nanoindentation}}, number = {{4-5}}, pages = {{9–18}}, title = {{{Nachbildung und Analyse von Schadensmechanismen bei Dichtringen im tribologischen Ersatzsystem}}}, doi = {{10.30419/TuS-2019-0019}}, volume = {{66}}, year = {{2019}}, }