Smart machine elements by rotary swaging - Manufacturing and Applications

This contribution presents a two-stage rotary swaging process, which allows integration of functional elements for load and condition monitoring of hollow tubular machine parts. The forming process is adjusted in order to guarantee a damage-free integration of the fragile functional elements. An effective utilization of the sensory compound requires the elements to lie in the path of forces which is ensured by a pretension. In order to set up the targeted pretensions, the integrated sensory elements can be utilized during the forming process. Two monitoring applications illustrate the coupling quality of the manufactured smart machine elements.