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Dipl.-Ing. Jan Schwennen

Research Associate
department: Machines, Equipment and Process Automation
office hours: to be agreed
room: 128, Geb. 50.36
phone: +49 721 608-41674
fax: +49 721 608-45005
Jan SchwennenXmq0∂kit edu

 Campus Süd

Dipl.-Ing. Jan Schwennen

Area of Research:

  • Automation and robotics
  • Production techniques for electric mobility
  • Joining technologies for multi-material-deigns
  • Manufacturing of electric motors
  • Big data analytics of manufacturing processes
  • Industry 4.0 applications
  • Augmented reality


General tasks:



  • SMiLE - Systemintegrativer Multi-Material-Leichtbau für die Elektromobilität
  • AnStaHa - Anlagentechnik für Fertigung von Statoren mit Hairpin-Technologie
  • SPP1712 - Intrinsische Hybridverbunde für Leichtbautragstrukturen


Test benches:


[ 1 ] Fleischer, J.; Koch, S.; Gebhardt, J.; Schwennen, J. & Wagner, H. (2014), "Intrinsische Hybridverbunde für Leichtbautragstrukturen". Thermoplastische Faserverbundkunststoffe, eds. Dietmar Drummer, pp. 199-207.
Der Einsatz von Leichtbautragstrukturen bietet heutzutage die Möglichkeit eine signifikante Gewichtsreduzierung zu realisieren. Die optimale Gesamtstruktur be-steht aus einer hybriden Werkstoffkombination, dem sogenannten Multi-Material-Design. Der Ansatz der Hybridisierung von Strukturkomponenten kann grundsätz-lich nach zwei Methoden erfolgen. Zum einen können die gefügten Hybridverbun-de durch nachgeschaltete Fügeoperationen, wie bspw. Kleben oder Schrauben hergestellt werden. Diese Methoden sind bereits etabliert, schöpfen jedoch das Leichtbaupotential nicht völlig aus. Zum anderen ist die Herstellung in einem ein-stufigen Prozess möglich, wobei die Verbindung der verschiedenen Materialien im Ur- oder Umformprozess erfolgt. Hierdurch wird ein sogenannter intrinsischer Hybrid geschaffen. Die Grundlagen für die ressourceneffiziente Fertigung, Charakterisie-rung und Auslegung lastoptimierter, intrinsischer Hybridbauteile für Leichtbautrags-trukturen werden seit 2014 im DFG Schwerpunktprogramm SPP 1712 (www.spp-1712-hybrider-leichtbau.de) erarbeitet.

[ 2 ] Ballier, F.; Schwennen, J.; Berkmann, J. & Fleischer, J. (2015), "The Hybrid RTM Process Chain: Automated Insertion of Load Introducing Elements during Subpreform Assembling". Progress in Production Engineering , eds. Jens P. Wulfsberg, B. R. A. T. M., pp. 312-319.
Fiber reinforced plastics are increasingly employed in the automobile industry. The process chain of resin transfer molding offers one approach for realizing structural components made of fiber reinforced plastic in high quantities. In order to increase economic efficiency, automated solutions for the subpreform assembly are required. There is also the need for mechanically highly stressable and at the same time economical joining techniques for joining fiber reinforced plastics with metal. The following article shall provide an approach to meet both of these requirements.

[ 3 ] Schwennen, J.; Sessner, V. & Fleischer, J. (2016), "A New Approach on Integrating Joining Inserts for Composite Sandwich Structures with Foam Cores". Procedia CIRP, eds. Rikard Söderberg, pp. 310-315.
Due to their high potential in lightweight designs composite sandwich structures with foam cores are gaining in importance in the automotive industry. To carry localized loads, sandwich structures require load introduction elements. In current solutions applied in the aerospace industry the inserts are embedded after the sandwich panels have been manufactured. This is very time consuming and therefore too expensive for automotive industry. In this paper, two new approaches are investigated experimentally, where the inserts get integrated during the preforming process or during the foam core manufacturing. With these manufacturing methods the performance and failure behavior of various insert geometries and different foam core densities will be determined by static pull out tests.

[ 4 ] Wang, Z.; Riemer, M.; Koch, S.; Barfuss, D.; Grützner, R.; Augenthaler, F. & Schwennen, J. (2016), "Intrinsic Hybrid Composites for Lightweight Structures: Tooling Technologies". WGP Congress 2016: Progress in Production Engineering, eds. Wulfsberg, J. P.; Fette, M.; Montag, T. & Trans Tech Publications, T. T. P., pp. 247-254.
The increasing use of hybrid materials requires efficient manufacturing processes. With the concept of the intrinsic hybrids the shaping or forming of the part is combined with the hybridization in the same process step and thereby the same tool. Hence new tooling concepts, which realise the process requirements, are necessary. This paper describes tooling concepts and design methods for the manufacturing of intrinsic hybrid parts. Different solutions for rotational and planar parts with thermosetting or thermoplastic matrix material are presented. Additionally the integration of inserts in such tools is discussed. Finally the main challenges for the design of tools for intrinsic hybrids will be presented.

[ 5 ] Schwennen, J.; Kupzik, D. & Fleischer, J. (2017), "Development of a calculation model for load introduction elements integrated during frp sandwich structure manufacturing". SAMPE Seattle 2017 : conference: May 22-25, 2017, exhibition: May 23-24, 2017, Washington State Convention Center, Seattle, Washington, eds. Blohkowiak, K., pp. 969-983.
Due to their high lightweight potential, FRP sandwich structures with foam cores are becoming increasingly important in the automotive industry. In order to accommodate local forces, load introduction elements are required. This work is part of a project in which the geometry is optimized for maximum load capacity, while taking into consideration the cost and the process restrictions. This paper deals with the creation of a suitable FEM model for investigating the effects of geometrical changes of the load introduction element on the load capacity. For this purpose, parameters of the foam and the insert material are determined experimentally. Subsequently, simulation examples are constructed using different solution methods, then compared and evaluated for applicability for an automatic optimization process. The result of the work shows that particularly three-dimensional models, which are explicitly solved, can deliver good results. The simulation results correspond very well to the experimentally determined tensile test curves.

[ 6 ] Schwennen, J.; Kalbhenn, L.; Klipfel, J.; Pfeifle, J.; Kupzik, D. & Fleischer, J. (2017), "Evolutionary Optimization of the Failure Behavior of Load Introduction Elements Integrated During FRP Sandwich Structure Manufacturing". Procedia CIRP, eds. Roberto Teti, D. M. D., pp. 410-415.
Due to their high lightweight potential, fiber-reinforced-plastics (FRP) sandwich structures with foam cores are becoming increasingly important in the automotive industry. To accommodate local forces, load introduction elements called inserts are required. A new type of insert is integrated into the sandwich panel during manufacturing. To accelerate the design and development process of these inserts, an optimization framework is developed based on the Abaqus CAE package and the Python programming language. An automated parametric nonlinear finite-element method (FEM) model is used to evaluate the performance of insert geometries. This model is integrated into an optimization routine based on a genetic algorithm. The population-based approach is very scalable through parallelization and shows accurate results within reasonable processing times.

[ 7 ] Gebhardt, J.; Schwennen, J.; Lorenz, F. & Fleischer, J. (2018), "Structure optimisation of metallic load introduction elements embedded in CFRP", Production Engineering, pp. 131-140.
The combination of construction parts made of fibre-reinforced plastics (FRP) and metal holds great lightweight design potential but places high demands on the necessary joining technologies. Metallic load introduction elements that are embedded in the manufacturing process of FRP components are a promising joining technology. In order to fully exploit the potential of this technology, approaches to increase the load bearing capacity of inserts, particularly under pull-out loads, have been missing. The aim is therefore to derive a method for the simulative structural optimisation of embedded inserts. The load bearing capacity increases under pull-out loads through smoothing of failure-critical stress peaks using the optimisation of the thickness distribution of the insert’s base plate. The increase of the load bearing capacity of the optimised insert geometry is confirmed through experimental validation.

[ 8 ] Muth, M.; Schwennen, J.; Bernath, A.; Seuffert, J.; Weidenmann, K. A.; Fleischer, J. & Henning, F. (2018), "Numerical and experimental investigation of manufacturing and performance of metal inserts embedded in CFRP", Production Engineering, pp. 141-152.
Due to their outstanding specific mechanical properties, carbon fibre reinforced plastics (CFRP) exhibit a high application potential for lightweight structures. With respect to multi-material design and to avoid drilling of structural CFRP parts to join them to other components, embedded metal elements, so called inserts, can be used. The inserts consist of a shaft and a baseplate which is embedded between the fibre layers. So far, only punctiform inserts have been subject to research. One feasible geometry are linear inserts which have not been studied yet. In this work, the performance of two different types of linear inserts will be investigated. The shapes are based on a punctiform insert which is made out of a threaded shaft welded onto a baseplate whose performance under different types of loading has been investigated before. The first type of linear inserts has the same cross-section as the reference punctiform insert but is of a linear form. The second type is a quasi-linear insert which consists of a baseplate with the same dimensions as the first linear inserts and three threaded shafts welded onto it. All samples are manufactured by resin transfer moulding (RTM). Depending on the geometry of the insert and the preforming concept it is potentially possible to maintain the fibre continuity. For the inserts with a continuous shaft and in the proximity of the insert, it is necessary to cut fibres of the top layers which are aligned perpendicular to the shaft. For the quasi-linear insert, it is possible to maintain the fibre continuity as the fibres are guided around the circular shafts. Additional to mechanical tests that are carried out, mould-filling and curing simulations are performed for different inserts to analyse the influence of the process parameters onto the part quality. In the main series of tests, the specimens are characterized regarding their failure behaviour and load bearing capacity under quasi-static loads. The results of the experiments show that, compared to the punctiform reference insert, the linear load introduction elements exhibit higher load bearing capacity. However, the linear load introduction elements are inferior regarding specific load bearing capacity and furthermore increase process complexity during preforming and production.