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

作者： Jing, Yuan Gong, Guanchen Hänel, Albrecht Ihlenfeldt, Steffen Fraunhofer Insitute for Machine Tools and Forming Technology IWU Chemnitz Germany Chair of Machine Tools Development and Adaptive Controls Institute Fo Mechatronic Engineering Technische Universität Dresden Dresden Germany

Industry 4.0 has significantly improved data efficiency by leveraging key technologies such as the Internet of Things and machine Learning. Among these key technologies, digital twins stand out by offering a promising approach to intelligently utilize this data. In the virtual representation of a physical asset, data reflects the conditions of the physical entity, while models simulate and predict its behavior. In this paper, a hybrid cutting force model is proposed for digital twins of helical end mills, focusing on cutting force analysis during the utilization phase of the machining process. This model combines a fairly mature physical process modelling approach with a data-driven method, specifically a neural network trained on real process data, to address the limitations inherent in their respective applications. The physics-based model provides meaningful constraints on the neural network's training, ensuring reliable cutting force prediction, particularly in scenarios with limited process data availability. The cutter's profile, generated by the geometric model, and the cutter-workpiece engagement maps, derived from the virtual machining model, together serve as inputs for the hybrid cutting force model. © 2025 The Author(s).

关键词： Machining centers

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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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Combined Evaluation of Digitalization and Sustainability Maturity of Small and Medium Sized Enterprises 19th

Combined Evaluation of Digitalization and Sustainability Mat...

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19th Global Conference on Sustainable Manufacturing, GCSM 2023

作者： Münnich, Marc Schönfelder, Annabell Stange, Maximilian Süße, Marian Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

ISBN: (纸本)9783031774287

Sustainability and digitalization are of high importance for companies to stay competitive and cope with market requirements from internal and external stakeholders. Especially the current changes in reporting standards and frameworks increase pressure to quickly adapt internal processes and acquire the relevant data. In this context, Industry 4.0 (I4.0) is discussed to enable companies to also foster sustainability. But many small and medium sized enterprises (SME) lack of experience and capacity and need support from experienced partners to develop suitable strategies and implement technologies. Appropriate support comprises general guidance through these domains and an evaluation of current and desired state of expertise to choose suitable actions. Maturity models (MM) are well-established to initiate and support the transformation of corporate structures. There are many models available that support digital and sustainable transformation, but almost no models are available that include both dimensions what results in decoupled developments in these domains. Hence, this contribution introduces a combined model for both domains and systematically describes the extension of an existing digitalization MM (DMM) that also considers rebound effects. The MM is tested within an industrial context use case. The results are evaluated and discussed for further development of the model and workflow. © The Author(s) 2025.

关键词： Sustainable development goals

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Integrating Hybrid Physics-Data Approaches for Enhanced Cutting Force Modeling in Digital Twins of Helical End Mills

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Procedia CIRP 2025年 133卷 358-363页

作者： Yuan Jing Guanchen Gong Albrecht Hänel Steffen Ihlenfeldt Fraunhofer Insitute for Machine Tools and Forming Technology IWU Chemnitz Germany Chair of Machine Tools Development and Adaptive Controls Institute fo Mechatronic Engineering Technische Universität Dresden Dresden Germany

Industry 4.0 has significantly improved data efficiency by leveraging key technologies such as the Internet of Things and machine Learning. Among these key technologies, digital twins stand out by offering a promising approach to intelligently utilize this data. In the virtual representation of a physical asset, data reflects the conditions of the physical entity, while models simulate and predict its behavior. In this paper, a hybrid cutting force model is proposed for digital twins of helical end mills, focusing on cutting force analysis during the utilization phase of the machining process. This model combines a fairly mature physical process modelling approach with a data-driven method, specifically a neural network trained on real process data, to address the limitations inherent in their respective applications. The physics-based model provides meaningful constraints on the neural network’s training, ensuring reliable cutting force prediction, particularly in scenarios with limited process data availability. The cutter’s profile, generated by the geometric model, and the cutter-workpiece engagement maps, derived from the virtual machining model, together serve as inputs for the hybrid cutting force model.

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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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Coupled CFD model of tool environment and workspace to determine the convective heat transfer in jet cooling of milling processes in machine tools 20

Coupled CFD model of tool environment and workspace to deter...

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

作者： Brier, Steffen Geist, Alexander Glänzel, Janine Naumann, Christian Regel, Joachim Dix, Martin Ihlenfeldt, Steffen Chemnitz University of Technology Professorship Production Systems and Processes Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany Technical University Dresden Institute for Machine Tools Development and Adaptive Controls Helmholtzstraße 10 Dresden01069 Germany

The responsible use of resources is an essential part of the manufacturing of industrial products. This includes the economical use of cooling lubricant and requires precise knowledge of the cooling mechanisms and their effect on the accuracy of the machine tool and thus the thermal error. A temporal and spatial resolution of the dynamic coolant flow near the tool and in the entire workspace in a single model would require a large simulation time. Therefore, a composite model was developed, that consists of a near-tool model and a larger surrounding workspace model. The required static near-tool cooling lubricant distribution is obtained via data discretization methods from a separate static simulation that resolves the turbulence of the cooling lubricant created by the tool rotation. The identified coolant distribution is integrated into a CFD near-tool model (with simplified tool geometry) which is coupled with a surrounding CFD workspace model. The workspace model is thus able to identify the effects of the coolant wetting on the machine surface temperature and finally, using thermo-elastic FEM simulations, on the resulting thermal error. This approach allows the composite model to simulate the entire workspace with reduced simulation effort and map the coolant-influenced heat transfer coefficients on the machine surface. © 2025 The Author(s).

关键词： Milling machines

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Coupled CFD model of tool environment and workspace to determine the convective heat transfer in jet cooling of milling processes in machine tools

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Procedia CIRP 2025年 133卷 280-285页

作者： Steffen Brier Alexander Geist Janine Glänzel Christian Naumann Joachim Regel Martin Dix Steffen Ihlenfeldt Chemnitz University of Technology Professorship Production Systems and Processes Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Technical University Dresden Institute for Machine Tools Development and Adaptive Controls Helmholtzstraße 10 01069 Dresden Germany

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Process Design for Hybrid Sheet Metal Components

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Acta Metallurgica Sinica(English Letters) 2015年第12期28卷 1518-1524页

作者： Rico Haase Roland Müller Dirk Landgrebe Peter Scholz Matthias Riemer Fraunhofer Institute for Machine Tools and Forming Technology IWU

The global trends towards improving fuel efficiency and reducing CO;emissions are the key drivers for lightweight solutions. In sheet metal processing, this can be achieved by the use of materials with a supreme strength-toweight and stiffness-to-weight ratio. Besides monolithic materials such as high-strength or light metals, in particular metal–plastic composite sheets are able to provide outstanding mechanical properties. Thus, the adaption of conventional, wellestablished forming methods for the processing of hybrid sheet metals is a current challenge for the sheet metal working industry. In this work, the planning phase for a conventional sheet metal forming process is studied aiming at the forming of metal–plastic composite sheets. The single process steps like material characterization, FE analysis, tool design and development of robust process parameters are studied in detail and adapted to the specific properties of metal–plastic composites. In material characterization, the model of the hybrid laminate needs to represent not only the mechanical properties of the individual combined materials, but also needs to reflect the behaviour of the interface zone between *** on experience, there is a strong dependency on temperature as well as strain rate. While monolithic materials show a moderate anisotropic behaviour, loads on laminates in different directions generate different strain states and completely different failure modes. During the FE analysis, thermo-mechanic and thermo-dynamic effects influence the temperature distribution within tool and work pieces and subsequently the forming behaviour. During try out and production phase,those additional influencing factors are limiting the process window even more and therefore need to be considered for the design of a robust forming process. A roadmap for sheet metal forming adjusted to metal–plastic composites is presented in this paper.

关键词： Characterization Hybrids Interface Layered structures Processing Sheet forming

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SF6 Plasma Surface Modification of Flax Fibers for Improved Adhesion in Polypropylene Composites

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Fibers and Polymers 2025年第6期26卷 2569-2579页

作者： Veiga, Anderson Thiago Vasconcelos da Silva, Yuri Ferreira Cavalcante, Rafael Cordeiro Simão, Renata Antoun Metallurgical and Materials Engineering Program COPPE Federal University of Rio de Janeiro Av. Horácio Macedo 2030 F-213 RJ Rio de Janeiro21941-599 Brazil Department of Wood Science Faculty of Forestry The University of British Columbia 2424 Main Mall VancouverBCV6T 1Z4 Canada Université Paris-Saclay SFR Condorcet FR CNRS 3417 3 Rue Des Rouges Terres Pomacle51110 France Fraunhofer Institute for Machine Tools and Forming Technology IWU Theodor-Körner-Allee 6 Saxony Zittau02763 Germany

Flax fibers have attracted growing interest in the automotive industry as an eco-friendly reinforcement for polymer composites. However, their limited interfacial compatibility with hydrophobic matrices is detrimental to adhesion, a key factor in the composite mechanical behavior. To address this issue, this study investigates the surface modification of flax fibers using sulfur hexafluoride (SF6) plasma. The proposed treatment promotes fiber surface hydrophobization while preserving their bulk properties. The effect of SF6 plasma treatments on flax fiber adhesion to polypropylene (PP) blends containing post-consumer material is thoroughly examined. The analysis, conducted using scanning electron microscopy, thermogravimetric analysis, X-ray photoelectron spectroscopy, and infrared spectroscopy, reveals that the plasma treatment induces the etching of amorphous substances present in the fibers, including amorphous cellulose, hemicelluloses, and lignin. Plasma etching in combination with fluorination significantly enhances the adhesion of flax fibers to the PP blend matrix. Notably, the treated fibers exhibit improvements in tensile strength (9%) and elastic modulus (25%) compared to untreated fibers. These findings highlight the potential of SF6 plasmas as an effective pretreatment method for natural fiber composite reinforcements. © The Author(s), under exclusive licence to the Korean Fiber Society 2025.

关键词： Sulfur hexafluoride

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Manufacturing of Long Products Made of Innovative Lightweight Materials

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Acta Metallurgica Sinica(English Letters) 2015年第12期28卷 1496-1502页

作者： Karsten Richter Roland Müller Andreas Kunke Verena Kr? usel Dirk Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Professorship Forming and Joining (UFF) Technische Universit?t Chemnitz

The processing of innovative lightweight materials to sheet metal components and assemblies with globally or locally defined properties is the object of this work. It takes a load-dependent design of components and assemblies, for example, based on the composition of different construction materials or a targeted setting of component areas with specified characteristics to fully exploit the lightweight potential when substituting conventionally used materials. Different process chains for the manufacturing of roll-formed long products made of magnesium alloys and high-strength steels with locally defined properties will be presented in this paper. Depending on the kind of material to be formed and the desired product characteristics, different temperature managements are needed for capable processes. Due to limited formability at room temperature, magnesium alloys require a heating of the forming zones above 200–225 °C throughout the bending process in order to activate additional gliding planes and to avoid any failures in the radii. The realization of local hardening effects requires at least one process-integrated heat treatment when roll forming manganese–boron steels. For both processes, it is imperative to realize a heating and cooling down or quenching appropriate for the manufacturing of long products with the required quality. Additionally, proper line speeds that allow a continuously operated economical production have to be considered. Research results including design, FEA, realization and experimentation of the mentioned process chains and strategies will be described in detail.

关键词： Roll forming Heat treatment Lightweight component Light metals Manganese steels AZ31 magnesium alloy

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