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17th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2023

作者： Fritzsche, Rayk Jager, Erik Head of Group Adaptable Assembly Systems Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Scientific Employeeat Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

For production of aircraft doors using innovative lightweight materials, a fully automated assembly process was developed. Therefor a door structure of an overwing-exit-door is to be joined from thermoplastic composite material components. The innovative material enable the use of new joining concepts. The assembly process was virtually simulated in order to forecast production time, process sequence, provision of operating resources and investment costs. Relevant manufacturing equipment was designed and accessibilities of the clamping and joining tools as well as collision areas were determined and optimized. To quality management, process control concept was developed with which geometric deviations of the components can be automatically compensated. © 2024 Elsevier B.V.. All rights reserved.

关键词： Process control

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Manufacturing of complex NiTi geometries with LPBF and adapted scanning strategies

Manufacturing of complex NiTi geometries with LPBF and adapt...

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2024 International Conference on Shape Memory and Superelastic Technologies, SMST 2024

作者： Herzig, Sandra Eckert, Medardus Müller, Bernhard Weisheit, Linda Thielsch, Juliane Drossel, Welf-Guntram Holtzhausen, Stefan Koch, Peter Schleyer, Mario Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Dresden University of Technology Dresden Germany Fraunhofer Institute for Mechanics of Materials IWM Freiburg Germany

ISBN: (纸本)9781627084840

NiTi shows a very promising combination of properties among different shape memory alloys. However, machining NiTi is a challenging task, making the manufacturing of complex geometries hard to nearly impossible using conventional manufacturing routes. As a result, the material’s full potential of the material has not been harnessed. The pseudoelastic properties of bulk NiTi are restricted to an 8 % strain [1]. Additive manufacturing of NiTi using laser powder bed fusion (LPBF) has been demonstrated as a successful alternative production route [2], capable of exhibiting pseudoelastic behavior even in the as-built state [3]. Existing literature has shown that modifications of the processing parameters can change the properties of Ni-rich NiTi significantly [4], which can be utilized intentionally to control the pseudoelastic properties in LPBF-manufactured NiTi. The fabrication of porous and lattice structures using LPBF allows to attain specific properties. This is achieved not only through the adjustment of the laser parameters and scanning pattern but also by enabling the creation of specifically tailored feature sizes and geometrical designs, such as unit cell design, the number and distribution of unit cells, and gradation. These geometrical structures go beyond the conventional unit cell designs (like the bcc unit cell), and when combined with the unique material behavior, they can result in extraordinary properties. It is possible to create a programmable material whose behavior can follow a logical description. The influence of lattice structure geometry and manufacturing parameters on the mechanical and functional performance will be discussed in the following. In addition, we present a structure whose stiffness behavior follows an if-then-else statement regarding to the effective strain and permits an effective strain exceeding 20 % without failure. The structure can be implemented in a planar clamping element which allows an adjustment to different shapes b

关键词： Titanium alloys

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Integrating Hybrid Physics-Data Approaches for Enhanced Cutting Force Modeling in Digital Twins of Helical End Mills 20

Integrating Hybrid Physics-Data Approaches for Enhanced Cutt...

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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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reProd® – Resource-Autarkic Production Based on Secondary Semi-finished Products 18th

reProd® – Resource-Autarkic Production Based on Secondary ...

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18th Global Conference on Sustainable Manufacturing, GCSM 2022

作者： Werner, Markus Haase, Rico Hermeling, Christian Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9783031288388

This paper presents a novel approach of a smart shortened material loop for producing second-life metallic components by saving a significant amount of energy and CO2 emissions. The focus is on metallic components and manufacturing chains based on adapted forming technologies. Sourcing and using secondary semi-finished products instead of virgin metallic materials facilitates the omission of process steps, such as iron smelting, steel making, continuous casting, hot and cold rolling, which involve the highest energy consumption and the highest CO2 emissions. Besides the positive impacts on sustainability, there are still scientific and technological challenges. One challenge lies in matching providers of secondary semi-finished material to market needs;the other comprises engineering the forming process chain while some material characteristics are not clearly specified or vary in a wide range. In contrast to the heavily restricted properties of virgin material, the characteristics of secondary semi-finished materials vary in a wider range and need to be elaborated. In the end, a new component will be produced, differing in design, function, and properties from conventional, single-life cycle products. Therefore, this paper introduces a novel, circular material loop for metals. The paper finishes with a short concept note on digital material and product passports to store and provide the required information on properties. © 2023, The Author(s).

关键词： Continuous casting

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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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Modeling the Impact of Laser Powder Bed Fusion on Nd-Fe-B Permanent Magnets

Modeling the Impact of Laser Powder Bed Fusion on Nd-Fe-B Pe...

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2023 IEEE International Magnetic Conference - Short Papers, INTERMAG Short Papers 2023

作者： Thielsch, Juliane Bittner, Florian Drossel, Welf-Guntram Fraunhofer Institute for Machine Tools and Forming Technology Iwu Dresden01187 Germany Chemnitz University of Technology Institute for Machine Tools and Production Processes Chemnitz09126 Germany

ISBN: (纸本)9798350338362

Statistical modelling was successfully applied to Laser Powder Bed Fusion (LPBF) of Nd-Fe-B permanent magnets to identify the potential impact of different process parameters and their interactions on resulting magnetic properties. Process models for the magnetic properties coercivity Hc, remanence Jr as well as for the shape of the demagnetization curve are obtained. The model quality for Hc is excellent (R2 = 0.99). The model for Jr only allows a rough statement on the impact of the LPBF process due to a weaker quality of the model (R2 = 0.77). It will not be possible to maximize Hc and Jr of LPBF manufactured Nd-Fe-B magnets at the same time due to their contrary dependencies on different LPBF parameters. We have predicted an optimized parameter set with a resulting high Hc of 816 kA/m and a maximized Jr of 0.65 T. From these properties and the calculated shape of the demagnetization curve we predict a (BH)max of 60.77 kJ/m3 for a magnet processed on a LPBF machine AconityMINI using MQP™-S powder. © 2023 IEEE.

关键词： Permanent magnets

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Virtual sensor for monitoring the geometric and kinematic accuracy of machine tools 19

Virtual sensor for monitoring the geometric and kinematic ac...

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19th CIRP Conference on Modeling of Machining Operations, CMMO 2023

作者： Doerrer, Felix Otto, Andreas Kolouch, Martin Rentzsch, Hendrik Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

The performance of machine tools depends on their working accuracy. The paper presents a new approach for in-process monitoring the geometric and kinematic accuracy of a machine tools. This approach utilizes a virtual sensor for capturing displacements at the tool center point (TCP). The virtual sensor is set up by using a data-driven approach based on extended transmissibility functions. The input data for monitoring are the NC internal data. The transmissibility functions are established via standard experimental procedures such as double ball bar (DBB) tests tests and estimation of frequency response functions (FRF). The data from the virtual sensor can be used for process monitoring and troubleshooting when launching a new process. © 2023 Elsevier B.V.. All rights reserved.

关键词： machine tools

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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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Data preparation for AI-based robot control 16

Data preparation for AI-based robot control

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

作者： Abdolmohammadi, Tina Ahrens, Antje Richter-Trummer, Valentin Todtermuschke, Marcel Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 Chemnitz09126 Germany

Roll-profiling is traditionally used for low-cost, high-volume manufacturing. However, complex sheet metal parts usually require labor-intensive forming processes, including post-forming straightening processes, to achieve optimal tolerances, thus increasing cost. Robotic roll-profiling already paves the way for single-part manufacturing. The current work focuses on developing the foundations for AI-based control strategies for in-line straightening, eliminating the need for post-forming straightening processes. Reaction forces and torques on the forming tool were analyzed and compared to part geometry reference measurements. Data processing and evaluation were developed, and different regression algorithms and neural networks were compared. © 2023 Elsevier B.V.. All rights reserved.

关键词： Data handling

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Process concatenation to reduce thermal changes in machine tools

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International Journal of Mechatronics and Manufacturing Systems 2022年第2-3期15卷 167-184页

作者： Wenkler, E. Selch, M. Hellmich, A. Ihlenfeldt, S. Institute for Machine Tools and Control Engineering Technische Universität Dresden Dresden01062 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden01069 Germany

Thermal effects in machine tools are responsible for a significant amount of produced scrap. Therefore, various approaches have been investigated and applied on machine tools to reduce thermal changes during manufacturing. Most of them target the machine tool and its operational state and can therefore just react to the thermal changes caused by the process. This paper shows how thermal changes can be reduced already in the manufacturing planning stage. With the use of a virtual numerical control (VNC) and loss models, power losses can be estimated, enabling the concatenation of processes to achieve minimal jumps in power loss from one process to another. Copyright © Inderscience Enterprises Ltd.

关键词： Energy efficiency

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