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Dynamic modeling of additive manufacturing process chains for end-use part manufacturing

Procedia CIRP 2021年 104卷 500-505页

作者： Mathias Wiese Antal Dér Alexander Leiden Tim Abraham Christoph Herrmann Sebastian Thiede Polymer Additive Manufacturing Center AUDI AG Auto-Union-Straße 1 Ingolstadt 85045 Germany Chair of Sustainable Manufacturing and Life Cycle Engineering Institute of Machine Tools and Production Technology Technische Universität Braunschweig Langer Kamp 19b Braunschweig 38106 Germany Fraunhofer Institute for Surface Engineering and Thin Films (IST) Bienroder Weg 54 E Braunschweig 38108 Germany Chair of Manufacturing Systems Department Design Production and Management University of Twente Drienerlolaan 5 Enschede 7522NB The Netherlands

Integration of additive manufacturing (AM) into series production demands for comprehensive methods and tools. An agent-based process chain simulation framework is proposed to embed AM into a cyber-physical production system. A multi-dimensional evaluation supports the planning of AM process chains as well as their day-to-day operation. The detailed evaluation possibilities down to product and single simulation event level are illustrated by a case study, in which an automotive exterior part is produced using the multi-jet fusion technology. Multiple possible process chain configurations are assessed based on their modeled key performance indicators, summarized in a energy value stream map.

关键词： Additive manufacturing Process chain simulation Rapid manufacturing Cyber-physical production systems Energy value stream analysis Multi-jet fusion

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Agent-based simulation for production planning and control in consideration of disruption events 49

Agent-based simulation for production planning and control i...

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49th International Conference on Computers and Industrial Engineering, CIE 2019

作者： Bui, M.D. Nguyen, Q.H. Kohl, H. Institute for Machine Tools and Factory Management Technical University of Berlin Germany Faculty of Engineering Vietnamese-German University Viet Nam Institute for Production Systems and Design Technology Fraunhofer-Gesellschaft Berlin Germany

An agent-based simulation (ABS) as a computer supported decision-making tool is presented for planning and evaluating job shop production. The presented approach focuses on short-term production planning and control. It allows planners to design and modify their models by describing all activities of workers and machines regarding operations related to the manufacturing process and tasks aided in the production. The simulated model was used for analyzing different operation modes and control strategies dealing with disruption events including machine breakdown, worker absence, and product defect. This provides an easy-to-implement simulation result through a description of coordinated actions and interactions of system resources. A case study for a remanufacturing job-shop shows effects of disruption events and reaction plans on the system performances. © 2019, Computers and Industrial Engineering. All rights reserved.

关键词： Planning

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Constructive methods to reduce thermal influences on the accuracy of industrial robots

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Procedia Manufacturing 2019年 33卷 19-26页

作者： Christian Mohnke Sascha Reinkober Eckart Uhlmann Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany Institute of Machine Tools and Factory Management Pascalstraße 8-9 10587 Berlin Germany

Due to their kinematics and their mobility, industrial robot systems offer a flexible, adaptable basis. An influencing variable, which is particularly relevant for processes with long process times, is the thermal heating and the associated thermal drift of the tool center point. The maximum deviation from the actual nominal position can reach up to 1.5 mm. To counteract these displacements, a cooling strategy or a targeted preheating can be installed. Both possibilities were evaluated under constructive, energetic and economic aspects and implemented on at least one axis of an industrial robot. Furthermore, a structural thermal decoupling and optimized design of the respective components were carried out. The results can help to reduce the influence of thermal heating and the associated thermal drift of the TCP by structural support without using cost-intensive measures with additional hardware and software on external computers for compensating the errors.

关键词： Robot Thermal Error Machining

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Energy optimal set-points for coupled systems using their topology*

Energy optimal set-points for coupled systems using their to...

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International Conference on Control, Decision and Information Technologies (CoDIT)

作者： Gregor Thiele Rico Clauß Theresa Johanni Jörg Krüger Fraunhofer Institute for Production Systems and Design Technology Berlin Germany Faculty of Electrical Engineering and Computer Science Technical University of Berlin Germany Institute for Machine Tools and Factory Management Technical University of Berlin Germany

ISBN: (数字)9781728159539

ISBN: (纸本)9781728159546

Energy efficiency is an emerging topic for companies in the industrial sector. The optimization of existing machines by advanced control is increasingly approached. For interconnected systems, we present a general procedure to include topology knowledge in an automated set-point optimization routine. This paper demonstrates an exemplary algorithm, applied to a parallel connection of two chillers for test purposes.

关键词： Optimization Mathematical model Topology Hysteresis Data models Interconnected systems Information technology

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Modeling energy and resource use in additive manufacturing of automotive series parts with multi-jet fusion and selective laser sintering

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Procedia CIRP 2021年 98卷 358-363页

作者： Mathias Wiese Alexander Leiden Christopher Rogall Sebastian Thiede Christoph Herrmann Polymer Additive Manufacturing Center AUDI AG Auto-Union-Straβe 1 Ingolstadt 85045 Germany Chair of Sustainable Manufacturing and Life Cycle Engineering Institute of Machine Tools and Production Technology Technische Universität Braunschweig Langer Kamp 19b Braunschweig 38106 Germany Chair of Manufacturing Systems Department Design Production and Management University of Twente Drienerlolaan 5 Enschede 7522NB The Netherlands Fraunhofer Institute for Surface Engineering and Thin Films (1ST) Bienroder Weg 54 E Braunschweig 38108 Germany

With additive manufacturing (AM) becoming a competitive manufacturing process for low to medium production volumes, rapid manufacturing becomes an increasingly relevant manufacturing approach. However, regulations and customers demand more eco-efficient life-cycles of products. This requires engineers and designers to pre-select between productive AM processes like selective laser sintering (SLS) and multi-jet fusion (MJF), based on their expected environmental impact in series production. As SLS already debuted in the mid-1980s, researches broadly explored parts’ mechanical properties, energy and resource use. The multi-jet fusion (MJF) technology, introduced in 2017, delivers comparable part properties at considerably higher print speeds. However, its energy and resource use is still scarcely covered. To close this gap, this publication develops a model for evaluation of energy and resource utilization based on a case study with an automotive exterior series part using an EOS P396 SLS and a HP 4200 MJF machine. Data from measurements in energy and material consumption as well as the print job shows a good predictability and builds the basis for an environmental assessment. The derived model and its functional blocks allow estimation and comparison of sustainability for different use cases in rapid manufacturing with MJF and SLS. Despite the process similarities, results concerning greenhouse gas emissions and cumulative energy demand are different. The gained insights enhance pre-selection of manufacturing strategies, a suitable printing technology and the evaluation of AM processes during manufacturing according to sustainability aspects. Printer manufacturers and users may find this research insightful for improvements in sustainability and comparability of future AM processes.

关键词： Rapid manufacturing Energy efficiency Resource efficiency Additive manufacturing Automotive engineering Process modeling

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Boron-doped CVD diamond micro-end mills for machining titanium 18

Boron-doped CVD diamond micro-end mills for machining titani...

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

作者： Uhlmann, E. Polte, M. Polte, J. Oberschmidt, D. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775121

In industry micro-milling tools made of cemented carbide are widely used. However, these micro-milling tools suffer from fast and random tool breakage during the machining of hard to machine materials. Therefore, in preliminary work micro-milling tools with cutting edges made of boron doped chemical vapour deposition (bdCVD) diamond were developed. In this work new micro-milling tools were successfully applied for machining titanium grade 2. Comprehensive cutting tests were carried out to analyse the influence of the spindle speed n, the feed per tooth ft, and the depth of cut ap on the surface roughness. Further experiments addressed the wear behaviour of the developed micro-milling tools. After a path length lc of 10 m a maximum width of flank wear land VBmax of 29 μm were observed. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： Milling (machining)

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Helical electrodes for improved flushing conditions in drilling EDM of MAR-M247 18

Helical electrodes for improved flushing conditions in drill...

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

作者： Uhlmann, E. Yabroudi, S. Perfilov, I. Schweitzer, L. Polte, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775121

The machining of precision holes in difficult to machine materials or alloys with high aspect ratios φ and under consideration of the cost-effectiveness of the overall process is still a challenge. Electro-discharge machining (EDM) is predestined for such purposes. Flushing is one key factor for the precise machining of bore holes with high aspect ratios φ. Nevertheless, the capabilities of the flushing conditions are often underrated regarding an improved process stability, an increased material removal rate VW, a decreased machining time tero, as well as the tool wear ΔIE. Therefore, the present investigation considers the influence of an outer geometry of cylindrical rod tool electrodes to improve the electro-discharge drilling process. Different electrodes made of brass, with helical flutes along the shank, are compared with the basic geometry, a cylindrical rod electrode, with respect to their flushing capabilities. All electrodes have an outside diameter d = 3 mm. It is suggested that the machining process will stabilise and the material removal rate VW will increase due to improved removal efficiency of erosion particles (debris). Through holes with a total depth h = 16 mm have been machined by use of design of Experiments (DoE) approved process parameters in nickel based superalloy MAR-M247. By use of a helical shaped electrode the machining time tero was reduced by 39 % compared to the cylindrical rod electrode. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： Electrodes

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Diamond burnishing for mould and die industry 18

Diamond burnishing for mould and die industry

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

作者： Uhlmann, E. Oberschmidt, D. Guhde, S. Polte, M. Polte, J. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775121

关键词： Surface roughness

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Electro-discharge drilling with MP-based carbon fibre electrodes 18

Electro-discharge drilling with MP-based carbon fibre electr...

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

作者： Uhlmann, E. Perfilov, I. Yabroudi, S. Schweitzer, L. Polte, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775121

For the electro-discharge drilling of micro-holes with small diameters D the production and the guidance of the tool electrode are most challenging. For holes with diameters D ≤ 50 μm the required electrodes have to be produced by electro-discharge dressing, which leads to a considerable increase in the production effort as well as the production costs. The small diameters 5 μm ≤ d ≤ 15 μm as well as the good electrical conductivity κ of carbon fibres make it possible to use a single carbon fibre as an electrode for electro-discharge drilling. The paper presents the results of experiments with non-rotating single carbon fibres as tool electrodes for electro-discharge drilling. The process parameters were optimised for the machining of through-holes in a workpiece made of stainless steel 1.4310 with a thickness h = 20 μm and h = 50 μm respectively. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： Carbon fibers

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Ductile machining of brittle materials for manufacturing micro-optic components 18

Ductile machining of brittle materials for manufacturing mic...

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

作者： Uhlmann, E. Oberschmidt, D. Rolon, D.A. Kühne, S. Jagodzinski, M. Malcher, M. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Germany

ISBN: (纸本)9780995775121

Due to the geometry and specification of micro-optic components, these may not be ground or polished, therefore they demand other manufacturing processes such as ultra-precision (UP) machining with defined cutting edge tools. Despite previous studies, the machining of brittle materials remains a challenge for manufacturing those components in UP processes. For example, ductile machining of silicon is extensively studied, however, ductile machining of materials such as Zerodur®, GaP, U.L.E.® and glass is still a challenge to overcome. Therefore, this paper aims at reporting the ductile or part-ductile machining of silicon and Zerodur® pieces in UP processes. Experiments were carried out using UP-shaping and plane turning processes in an UP-machine tool. Moreover, monocrystalline diamond tools were employed. During UP-turning experiments, the process forces were measured. The machining results were obtained by White Light Interferometer (WLI) of the representative machined surfaces. In order to complement the experiments, simulations were performed in finite element software to comprehend the influences of the rake angle on ductile machining of those materials. After the UP-shaping experiments, the depth of cut was determined for each of the mentioned materials together with the main influence of each process parameter. Furthermore, a reduction of parameter ranges for UPturning experiments was accomplished. Using design of Experiments for UP-turning tests, the main influences of process parameters were observed and detailed, together with tool geometry optimization and recommendation for further experiments. The local optimum of process parameters was found as well as the accomplishment of ductile removal during the machining tests. These results and simulation models are going to be further used for a more detailed process description, as analogous tests and optimization of UP processes such as micro-milling. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： design of experiments

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