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Effects of abrasive waterjet cutting on surface properties of hardened steel

Procedia CIRP 2023年 118卷 620-625页

作者： Nermin Redžić Philipp Kieweg Joachim Regel Martin Dix Chemnitz University of Technology Institute for Machine Tools and Production Processes Reichenhainer Str. 70 09126 Chemnitz Germany Franke GmbH Obere Bahnstraße 64 73431 Aalen Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

The importance of cutting hardened materials without influencing their structural properties makes abrasive waterjet machining a favorable choice in certain applications in comparison with other manufacturing technologies. Using this technology, faulty surface structures and errors caused by high thermal loads such as burrs, burns and cracks, can be avoided. In this paper, the results of applying the abrasive waterjet technology for cutting of hardened steel and its advantageous properties in comparison with cut-off grinding will be presented. The influence of process parameters on surface properties and burr formation has been determined by experimental analysis.

关键词： abrasive waterjet machining hardened steel cut-off grinding burr formation

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Study on flushing condition for improving silver deposition in silver nano-powder mixed EDM 22

Study on flushing condition for improving silver deposition ...

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22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022

作者： Bui, Viet D. Meinshausen, Ann-Kathrin Berger, Thomas Martin, André Harnisch, Karsten 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 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)9781998999118

Silver nano-powder mixed electrical discharge machining (PMEDM) has demonstrated its applicability for antibacterial surface modification. However, previous PMEDM studies indicated that jet flushing leads to a low powder concentration in the spark gap, which was the main reason for a low deposited silver content. Internal flushing with different dielectric pressures was therefore proposed and will be investigated in this study. To do so, Ti-6Al-4V hollow tool electrodes with an outer diameter of 3 mm and an inner diameter of 2.5 mm are selected to machine Ti-6Al-4V samples. Silver nano-powders with a size of 50 nm to 60 nm are suspended in the hydrocarbon-based dielectric fluid at a 5 g/l powder concentration. Surface roughness and resulting silver content and distribution on the modified surface are analysed and discussed. Results show that internal flushing significantly increases the deposited silver content when high pressure of the dielectric fluid was applied. In addition, with careful control, the internal flushing is a promising strategy for improving the uniformity of the deposited silver distribution. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Surface roughness

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An assessment method of machine components for usage-based value creation in complex manufacturing systems

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Procedia CIRP 2023年 120卷 225-230页

作者： Mohaned Alaluss Robin Kurth Anton Mauersberger Chris Drechsler Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Institute of Mechatronic Engineering Dresden University of Technology Helmholtzstr. 7a 01069 Dresden Germany

Rising demands on manufacturing technologies lead to an increase in the complexity of corresponding machines and systems. This complexity acts as an obstacle to the development and realization of digital, usage-based business models for complex manufacturing systems. Particularly in the case of pay-per-use business models, it is necessary to monitor the actual machine load in operation to minimize the business risk on the operator and supplier side. This complicates the transition towards data-oriented value creation in manufacturing system environment. To overcome this challenge, a novel method to assess machine components regarding their potential to monitor the actual load and usage behavior of the whole manufacturing system is proposed. On this basis, the transparency and therefore confidence in digital, usage-based value creation like pay-per-use business models can be increased. The resulting approach is demonstrated by taking the example of a sheet metal forming press.

关键词： Methodology Manufacturing Forning Service Decision making

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Replicative Production of Multifunctional Microfluidic Polymer Films for Biomedical Disposables

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Procedia CIRP 2024年 125卷 207-212页

作者： Eric Gärtner Frederic Schell Lukas Nitschke Richard Chukwudi Okafor Christoph Zwahr Claudia Hackl Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 09126 Chemnitz Germany Fraunhofer Institute for Material and Beam Science IWS Winterbergstr. 28 01277 Dresden Germany Leibniz Institute of Surface Engineering IOM Permoserstr. 15 04318 Leipzig Germany

Increasing demands on the reproducibility and accuracy of lab-on-a-chip systems in the life science sector require new tools for the molding of polymer films with spatially selectively functionalized surfaces. By applying local micro- and nanostructuring to the molding tools, the aim is to achieve multifunctionality of the polymer films, by setting certain wetting properties. This means that fluid-affecting properties (hydrophobic, hydrophilic) should be possible. To functionalize polymer films, the replication tools were specifically microstructured using laser-based surface functionalization. The periodic micro- and nanostructures were produced with the help of nanosecond pulsed and picosecond pulsed laser systems using Direct Laser Interference Patterning. For this purpose, complex functional microstructures in the range of 0.1 µm to 100 µm were developed based on a bionic approach. The functional properties were transferred in a one-step replicative process using UV-imprinting and were subsequently verified by determining the wetting behavior of the molded microfluidic films and the corresponding laser microstructured replication tools. This publication presents the successfully developed processes and the promising results of this series of experiments.

关键词： laser microstructuring surface functionalization lab-on-a-chip DLIP UV-imprinting

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Increasing Resilience of Production Systems by Dynamic Context Modelling and Process Adaption 16

Increasing Resilience of Production Systems by Dynamic Conte...

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

作者： Wunderlich, Tim Hansert, Jonas Koch, Sandro Heinrich, Robert Schlegel, Thomas Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany Karlsruhe University of Applied Sciences Moltkestr. 30 Karlsruhe76133 Germany Karlsruhe Institute of Technology Am Fasanengarten 5 Karlsruhe76131 Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden01062 Germany

The requirements for cyber-physical production systems (CPPS) grow steadily, leading to increased complexity of such systems. To address issues due to reconfiguration or failures, we present an approach to creating a context model of the CPPS components during runtime and to detect deviations from the planned production processes. Furthermore, we present a concept for modelling production processes that allows for dynamic process adaption during runtime. We then utilize this process adaption and the context model to cope with unforeseen failures and increase the resilience of the system. Finally, we evaluate the feasibility of our approach by applying it to an Industry 4.0 production system. © 2023 Elsevier B.V.. All rights reserved.

关键词： Dynamics

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Identifying efficiency and flexibility measures for energy-oriented factory management

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Procedia CIRP 2022年 105卷 302-307页

作者： Marc Münnich David Rein Heiner Reinhardt Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

Recent efforts in climate politics increase the ecological pressure of manufacturing companies in terms of intelligent and efficient usage of resources during operations. Rising energy prices lead to further economic pressure. Especially companies with a high share of energy cost on total costs are forced to continuously improve processes regarding the energy usage. Existing guidelines and methodologies are usually concerned with either of the two dimensions energy efficiency (EnEff), or energy flexibility (EnFlex). While EnEff addresses the reduction of the energy consumption for a defined manufacturing output, EnFlex addresses the advantageous shift, increase, and decrease of energy demand. Although both dimensions address the total reduction of cost, they are usually considered separately in literature. Here, we examine both dimensions while focusing on the provision and usage of electric energy due to its manifold conversion and usability opportunities in factory processes. Therefore, we developed an overview of measures of both dimensions as well as their application characteristics within the factory. To identify EnEff and EnFlex measures, a practicable methodology is introduced. This aims to enable especially companies with few experiences in EnEff and EnFlex measure application to improve energy aware operations. We illustrate our examination by means of an industrial application example.

关键词： Energy Energy efficiency Flexibility Factory

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Subjective hearing sensation of process variations at a milling machine. How reliable will chatter marks be detected? 50

Subjective hearing sensation of process variations at a mill...

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50th International Congress and Exposition of Noise Control Engineering, INTER-NOISE 2021

作者： Trautmann, Florian Knöfel, Björn Drossel, Welf-Guntram Troge, Jan Freund, Markus Penter, Lars Anders, Damian Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Strasse 44 Dresden01087 Germany University of Technology Dresden Dresden01062 Germany

ISBN: (纸本)9781732598652

Intuition enables experienced machine operators to detect production errors and to identify their specific sources. A prominent example in machining are chatter marks caused by machining vibrations. The operators assessment, if the process runs stable or not, is not exclusively based on technical parameters such as rotation frequency, tool diameter, or the number of teeth. Because the human ear is a powerful feature extraction and classification device, this study investigates to what degree the hearing sensation influences the operators decision making. A steel machining process with a design of experiments (DOE)-based variation of process parameters was conducted on a milling machine. Microphone and acceleration sensors recorded machining vibrations and machine operators documented their hearing sensation via survey sheet. In order to obtain the optimal data set for calculating various psychoacoustic characteristics, a principle component analysis was conducted. The subsequent correlation analysis of all sensor data and the operator information suggest that psychoacoustic characteristics such as tonality and loudness are very good indicators of the process quality perceived by the operator. The results support the application of psychoacoustic technology for machine and process monitoring. © INTER-NOISE 2021 .All right reserved.

关键词： Audition

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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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Ultrasonic Vibration assisted Silver Integration by Powder Mixed EDM for Antibacterial Surfaces 7

Ultrasonic Vibration assisted Silver Integration by Powder M...

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7th CIRP Conference on Surface Integrity, CSI 2024

作者： Bui, Viet D. Martin, André Berger, Thomas Harnisch, Karsten Döring, Joachim Bertrand, Jessica Schubert, Andreas Chemnitz University of Technology 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

Powder mixed electrical discharge machining (PMEDM) with silver nano-powder has demonstrated its potential capability in antibacterial surface modification. Analyses in the cross-sectional layer showed that silver was mainly integrated near the topmost surface layer, and its content is reduced within the layer towards the substrate. However, to achieve a long-term antibacterial efficacy, silver needs to be deeply integrated in the modified layer. Previous studies indicated that ultrasonic vibration (UV) assisted PMEDM can homogenize the silver content in the deposited layer. In this study, the effect of UV on the silver distribution within the modified layer is investigated. Ti6Al4V workpieces were stimulated by UV with a frequency of 22.3 kHz and an amplitude of 2.5 µm. Hydrocarbon-based dielectric fluid, mixed with silver nano-powder with concentrations up to 15 g/L, were internally flushed through a hollow tool with a pressure of 4 bar. PMEDM without UV was investigated for comparison. The layer thickness, micro-cracks and the cross-sectional distribution of deposited silver were analysed by confocal microscopy, scanning electron microscopy, and energy-dispersive X-ray spectroscopy. Results indicate that applying UV leads to the highest silver content in the middle region of the layer, a significant decrease of micro-cracks and a slight reduction of the layer thickness. © 2024 The Authors. Published by Elsevier B.V.

关键词： Scanning electron microscopy

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Definition and Description of Matrix Production Systems

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Procedia CIRP 2024年 130卷 1875-1880页

作者： Daniel Ranke Michael Trierweiler Patricia Berkhan Marc Münnich Thomas Bauernhansl Fraunhofer Institute for Manufacturing Engineering and Automation IPA Nobelstr. 12 70569 Stuttgart Germany Institute of Industrial Manufacturing and Management IFF Nobelstr. 12 70569 Stuttgart Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

The industry’s use of adaptable production systems, such as matrix production, is increasing. However, these systems vary in their specific details. The lack of a unified definition, delimitation, and description hinders comparability and the transfer of lessons learned between different systems. This paper aims to propose a comprehensive definition of matrix production and differentiation between different implementation forms. To achieve this, the paper first examines existing approaches to define and describe production systems and their manifestations. Various frameworks and models have been proposed in the literature, but they often focus on specific aspects of production systems, neglecting the complexity of matrix production. The paper identifies common elements and challenges in defining and describing production systems by analyzing these approaches. A second investigation analyzes various existing descriptions of matrix production from the scientific literature. While some definitions focus on the organizational structure, others emphasize operational aspects. By synthesizing these definitions, the paper proposes a comprehensive definition of matrix production encompassing both dimensions. Furthermore, the paper includes cases of industrial implementations as a third investigation. These cases provide insights into the practical application of matrix production systems across different industries. The paper identifies common characteristics, challenges, and benefits associated with matrix production by analyzing these implementation examples. Finally, all three investigations are combined to create a unified definition and a complementary descriptive model. The proposed framework provides a systematic approach to define and describe matrix production systems. It allows for a better understanding and comparison of different implementations, facilitates the transfer of lessons learned, and promotes the exchange of best practices. This framework will enable r

关键词： Matrix Production Framework Definition

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