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14th International Electric Drives Production Conference, EDPC 2024

作者： Psyk, Verena Fleischer, Linda Linnemann, Maik Bach, Mirko Dix, Martin Fraunhofer Institute for Machine Tools and Forming Technology Department Forming Technology Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (纸本)9798350356885

In the mobility industry and especially in case of electrically powered vehicles the implementation of lightweight powertrain components with high efficiency and minimum in-stallation space is of utmost importance. One approach to realize a particularly compact and light design is using a central motor, which is aligned with a planetary gearbox via coaxial (partly) hollow rotor shafts positioned one within the other to operate the left and right-hand wheels of the car. To enable further weight reduction, aluminium alloys might be considered for the hollow shafts instead of the conventionally used steel. When the electrical machine is assembled, the shafts must be firmly connected to the rotor core, which is typically made of laminated electrical steel core. Electromagnetic forming is a promising technology for joining tubular aluminium components with similar or dissimilar materials. In this paper, the suitability for the described joining task is investigated. For this purpose, an inductor specifically suitable for expanding a round tube into a non-rotationally symmetric cross section shape is suggested and the corresponding joining process is developed using coupled electromagnetic and structural mechanical simulation. Experimental validation is carried out using a technology demonstrator. © 2024 IEEE.

关键词： Epicyclic gears

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Structure and Validation of a Kinematic Surface Simulation Model for the ultrashort-pulse Direct-Laser-Writing Process 20

Structure and Validation of a Kinematic Surface Simulation M...

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20th CIRP Conference on Modeling of Machining Operations in Mons, CIRP CMMO 2025

作者： Wieland, Fabian Gärtner, Eric Wieland, Sebastian Fraunhofer Institute for Machine Tools and Forming Technology IWU Department Functional Surfaces and Micromanufacturing Reichenhainer Str. 88 Chemnitz09126 Germany

This paper presents the development and validation of a kinematic surface simulation model for the prediction of ultrashort-pulsed laser structured surfaces. The simulation is based on an existing kinematic simulation model for short-pulsed laser structuring and utilizes the stepwise Boolean intersection of a machined and digitized single point ablation with the workpiece to reproduce the microstructuring process. The existing short-pulse simulation model was extended by newly integrated description models to allow a more detailed representation of within the process changing influences, e.g. the surface fine-structure to enable a multi-layer processing. In addition, a reorganization of the simulation algorithm resulted in a general improvement of the run time and a resolution-independence. Based on the kinematic simulation principle, the manufacturing process for a wide range of material-machine combinations in the field of laser structuring can be described. The model enables a time-efficient, nanometer-resolved prediction of representative surfaces with a size of up to several square millimeters. Furthermore, complex influences such as material- and temperature-related properties do not need to be considered separately, as they are taken into account by the machined and digitized single point ablation. Compared to artificial intelligence approaches and numerical or multiphysical simulations, the need for preliminary studies is very low. Depending on the chosen laser machining parameters the simulation can reproduce the surface textures macro- and microstructure. © 2025 Elsevier B.V.. All rights reserved.

关键词： Kinematics

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Dismantling and remanufacturing strategies in the automotive sector 31

Dismantling and remanufacturing strategies in the automotive...

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31st CIRP Conference on Life Cycle Engineering, LCE 2024

作者： Haase, Rico Farioli, Daniele Selbmann, Rene Werner, Markus Kräusel, Verena Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz09126 Germany Politecnico di Milano Department of Mechanical Engineering Milan20156 Italy

The contemporary recycling of automobiles takes place on a very baseline material level. In order to fundamentally improve the ecologic footprint of the vehicle, a wider application of remanufacturing strategies is intended. Following different recycling approaches ranging from direct reuse or refurbishment through remanufacturing until repurpose, a well-aimed dismantling followed by manufacturing processes adapted to the post-consumer components is mandatorily required. For use on an industrial scale, environmental efficiency and economic viability must be balanced well. Within the paper, possible remanufacturing technologies and necessary prerequisites such as input data are discussed. For the design of remanufacturing operations, material properties and geometric information are a crucial starting point. Seamless integration of the specific properties is intended to encourage wider utilization of pre-used components and materials. With reference to the well-established process design for metal forming operations, adapted material cards and curvature equivalence values are proposed. The approach is illustrated by a reforming operation, where a brake disc cover is remanufactured from a used car body roof. © 2024 Elsevier B.V.. All rights reserved.

关键词： Recycling

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Joining of Laminated Core and Shaft of an Electric machine Rotor by Electromagnetic forming

Joining of Laminated Core and Shaft of an Electric Machine R...

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International Electric Drives Production Conference (EDPC)

作者： Verena Psyk Linda Fleischer Maik Linnemann Mirko Bach Martin Dix Department Forming Technology Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (数字)9798350356885

ISBN: (纸本)9798350356892

关键词： Shafts Space vehicles Shape Rotors Wheels Mechanical power transmission Topology Steel Electromagnetics Joining processes

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A No-Code Approach for Intuitive Robot Programming for Agile Welding Application

A No-Code Approach for Intuitive Robot Programming for Agile...

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International Workshop on Robot Sensing (ROSE)

作者： Jayanto Halim Mohamad Bdiwi Steffen Ihlenfeldt Group Collaborative Robot Systems Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Department of Production System and Factory Automation Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (数字)9798350362367

ISBN: (纸本)9798350362374

Agile manufacturing paradigms have revolutionized a new era of production processes, offering unparalleled flexibility and adaptability to the ever-changing landscape of product variations and smaller batch sizes. In response to this dynamic environment, the robotic industry has undergone a significant transformation, presenting a range of versatile robotic systems capable of swiftly deploying diverse applications. This transformative shift accelerates manufacturing processes and showcases the ability to accommodate product specifications and batch size variations. Welding is a notable example of robotics playing a crucial role in agile production. This work presents a novel approach combining no-code robot programming and an intelligent vision-based welding system. By leveraging this framework, even non-expert users can seamlessly instruct welding trajectories through intuitive interactions. These trajectories are meticulously crafted using advanced welding seam extraction algorithms, considering various welding joint types and inputs from heterogeneous sensors. Consequently, robot-specific parameters can be parametrized, and the generated robot code can seamlessly translate into robotic movements in the real world. Validation of this approach through real-world experiments underscores its potential for deployment in agile welding applications. The promising results affirm this novel methodology's efficacy, paving the way for its practical implementation in real-world scenarios. By effectively bridging the divide between advanced robotics and agile manufacturing, this approach can potentially elevate industrial robotic applications to new levels of efficiency and adaptability.

关键词： Agile manufacturing Service robots Welding Semantics Production Robot sensing systems Mathematical models

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Structure and Validation of a Kinematic Surface Simulation Model for the ultrashort-pulse Direct-Laser-Writing Process

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Procedia CIRP 2025年 133卷 227-232页

作者： Fabian Wieland Eric Gärtner Sebastian Wieland Fraunhofer Institute for Machine Tools and Forming Technology IWU Department Functional Surfaces and Micromanufacturing Reichenhainer Str. 88 Chemnitz 09126 Germany

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Silver-integrated EDM processing of TiAl6V4 implant material has antibacterial capacity while optimizing osseointegration

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Bioactive Materials 2024年第1期31卷 497-508页

作者： Hilmar Büssemaker Ann-Kathrin Meinshausen Viet Duc Bui Joachim Döring Vadym Voropai Adrian Buchholz Andreas J.Mueller Karsten Harnisch André Martin Thomas Berger Andreas Schubert Jessica Bertrand Department of Orthopaedic Surgery Otto-von-Guericke University MagdeburgGermany Professorship Micromanufacturing Technology Chemnitz University of TechnologyChemnitzGermany Institute of Molecular and Clinical Immunology Otto-von-Guericke University MagdeburgGermany Health Campus Immunology Infectiology and InflammationOtto-von-Guericke University MagdeburgMagdeburgGermany Institute of Materials and Joining Technology Otto-von-Guericke UniversityMagdeburgGermany Fraunhofer Institute for Machine Tools and Forming Technology ChemnitzGermany

Periprosthetic joint infections(PJI)are a common reason for orthopedic revision *** has been shown that the silver surface modification of a titanium alloy(Ti-6Al-4V)by PMEDM(powder mixed electrical discharge machining)exhibits an antibacterial effect on Staphylococcus *** the thickness of the silver-modified surface influences the adhesion and proliferation of bacteria as well as the ossification processes and in-vivo antibacterial capacity has not been investigated ***,the aim of this work is to investigate the antibacterial effect as well as the in vitro ossification process depending on the thickness of PMEDM silver modified *** attachment of *** on the PMEDM modified surfaces was significantly lower than on comparative control samples,independently of the tested surface *** proliferation,however,was not affected by the silver content in the surface *** observed a long-term effect of antibacterial capacity in vitro,as well as in *** induction of ROS,as indicator for oxidative stress,was observed in the bacteria,but not in osteoblast-like *** influence on the in vitro osteoblast function was observed,whereas osteoclast formation was drastically reduced on the silver *** changes in cell death,the metabolic activity and oxidative stress was measured in *** show that already small amounts of silver exhibit a significant antibacterial capacity while not influencing the osteoblast ***,PMEDM using silver nano-powder admixed to the dielectric represents a promising technology to shape and concurrently modify implant surfaces to reduce infections while at the same time optimizing bone ingrowth of endoprosthesis.

关键词： alloy silver powder

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Dismantling and remanufacturing strategies in the automotive sector

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Procedia CIRP 2024年 122卷 695-700页

作者： Rico Haase Daniele Farioli Rene Selbmann Markus Werner Verena Kräusel Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany Politecnico di Milano Department of Mechanical Engineering 20156 Milan Italy

关键词： circular economy automotive recycling dismantling remanufacturing secondary raw material pre-used components

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Effects of ultrasonic vibration on the silver deposition in powder mixed EDM for antibacterial surface modification 23

Effects of ultrasonic vibration on the silver deposition in ...

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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Bui, Viet D. Berger, Thomas Martin, André Harnisch, Karsten Döring, Joachim Bertrand, Jessica Schubert, Andreas Chemnitz University of Technology Institute for Machine Tools and Production Processes Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Otto-von-Guericke University Magdeburg Institute of Materials and Joining Technology Universitätsplatz 2 Magdeburg39106 Germany Otto-von-Guericke University Magdeburg Department of Orthopaedic Surgery Leipziger Str. 44 Magdeburg39120 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9781998999132

Previous studies have demonstrated that silver nano-powder mixed electrical discharge machining (PMEDM) is a potential technique for concurrent ablative shaping medical implants and generating antibacterial layers on the surfaces. PMEDM modified surfaces with deposited silver offer excellent antibacterial properties along with very good biocompatibility. However, for medical applications, PMEDM is still facing challenges providing sufficiently uniform distribution of deposited silver and preventing spattered layers that might lead to delamination from the modified surface. It was indicated that ultrasonic vibration (UV) has remarkable effects on the fluid dynamics in the spark gap, which positively affect the silver distribution and reduce the generation of spattered layers. Consequently, in this study, a Ti6Al4V workpiece is vibrated with an ultrasonic frequency of 22.3 kHz and an amplitude of 2.5 μm during the PMEDM process. The effect of vibration direction in X and Z axis on the silver deposition is evaluated while discharge energy is varied up to 125 μJ. For comparative analyses also PMEDM without vibration assistance is investigated. Ti6Al4V hollow tool electrodes with an outer diameter of 3 mm and an inner diameter of 2.5 mm are utilised for internal flushing with a pressure of 4 bar. A hydrocarbon-based dielectric fluid is mixed with silver nanopowder at a concentration of 15 g/l. Results show that UV assisted PMEDM increases the content of deposited silver up to 1.7 times compared to PMEDM without vibration. UV with vibration in Z direction and pulse energies of 55 μJ and 125 μJ results in uniform silver distribution and significantly decreases spattered layer formation, whereas the use of vibration in X-direction leads to negative effects. By carefully selecting machining conditions such as vibration direction and amplitude, wall thickness of hollow tool electrode and powder concentration, PMEDM provides surfaces with promising characteristics for medical

关键词： Medical applications

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Influence of engagement parameters on estimation of tangential cutting force using high-frequency process data of the machine tool 16

Influence of engagement parameters on estimation of tangenti...

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16th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2022

作者： Rytir, Michal Rönnecke, Jonas Hänel, Albrecht Kolar, Petr Ihlenfeldt, Steffen Czech Technical University in Prague Czech Institute of Informatics Robotics and Cybernetics Department of Industrial Production and Automation Jugoslávských partyzánu 1580/3 Prague160 00 Czech Republic Fraunhofer Institute for Machine Tools and Forming Technology IWU Department of Production Digital Twin Nöthnitzer Straße 44 Dresden Germany Technische Universität Dresden Institute of Mechatronic Engineering Chair of Machine Tools Development and Adaptive Controls Dresden01062 Germany

The machining of high-value products needs advanced quality control to avoid the risk of expensive follow-up operations performed on parts with unacceptable quality. This situation requires the in-process or close to in-process control of the machining operation. The tangential cutting force is a parameter that characterizes the force interaction between the specific workpiece material and the specific tool geometry. This paper presents a method for a tangential cutting force calculation along the given tool path based on processing of the high-frequency data acquired from the machine tool control system with support of the geometric material removal model. The calculated data are compared with the reference dynamometer results. The influence of the variable engagement parameters is demonstrated and discussed from the perspective of the in-process workpiece quality control. © 2023 Elsevier B.V.. All rights reserved.

关键词： machine tools

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