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Wishbone made of hybrid aluminum foam sandwich

Lightweight Design worldwide 2018年第2期11卷 36-41页

作者： Claudia Drebenstedt Camilo Zopp Alexander Hackert Lothar Kroll Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany TU Chemnitz Germany

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Investigating the potential of electrical discharge machining for antibacterial coating of titanium implants 18

Investigating the potential of electrical discharge machinin...

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

作者： Bui, Viet D. Mwangi, James W. Berger, Thomas Schubert, Andreas Technische Universität Chemnitz Prof. Micromanufacturing Technology Reichenhainer Strasse 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 Chemnitz09126 Germany

ISBN: (纸本)9780995775121

Titanium and titanium alloys are some of the best materials for medical implants owing to their excellent properties including biocompatibility, corrosion resistance and high fatigue strength among others. However, many implants have to be removed after implantation because of bacterial infection. Coating titanium implants with copper or silver has demonstrated antibacterial abilities and has therefore been widely applied to solve this problem. Ion implantation, physical vapour deposition, magnetron sputtering and many other different methods are used to coat these materials. However, until now, there is no method that allows for concurrent machining and coating of the antibacterial layer. Electrical Discharge Machining (EDM) has demonstrated its potential on surface modification owing to the fact that the material from tool electrode and/or powder mixed in dielectric fluid is implanted on the workpiece thereby changing its characteristics. In this study, the suitability of EDM for coating copper and silver on titanium alloy is investigated. Titanium alloy samples are machined using a high precision EDM machine and later analysed for surface quality and chemical composition. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： Titanium alloys

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Product Flexible Car Body Fixtures with Position-dependent Load Balancing Based on Finite Element Method in Combination with Methods of Artificial Intelligence

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Procedia CIRP 2018年 67卷 452-457页

作者： Rayk Fritzsche Andreas Richter Matthias Putz Head of group assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strae 88 Chemnitz 09126 Germany Scientific employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strae 88 Chemnitz 09126 Germany

In car-body production, the fixtures used for fixing the car-body panels during the joining processes predominantly consist of rigid constructions that are precise and specific for one car-model. In addition to the already presented automatic adaptation of such fixtures, and specific for the production of many different car-models using same fixture, different clamping robots have been developed. In order to meet the high quality requirements, the positional deviations of these clamping robots are adjusted due to different external loads. This control loop is carried out using a combination of finite element method, mathematical algorithms and modern methods of artificial intelligence.

关键词： Quality management Body in white Rramp up Artificial intelligence Neuronal network Database

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Methodology and model for predicting energy consumption in manufacturing at multiple scales

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Procedia Manufacturing 2018年 21卷 694-701页

作者： Jan Reimann Ken Wenzel Marko Friedemann Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

Certain fields of manufacturing, like casting, forming or cutting, may cause high energy load. Especially under the consideration of renewable energy sources it is beneficial to negotiate production schedules and consumption forecasts with the energy supplier. This would enable an optimized management of energy sources and infrastructure components on the supplier side, helping to reduce costs. Optimal and balanced expenses for production would be the consequence. The problem of power consumption prediction in manufacturing was subject of many studies in the past. Most of them either consider the physical modeling of processes at a very detailed level, or they introduce tailored prediction models for specific production processes. Thus, it is hard to apply their results to other uses cases in different scenarios. As a consequence, a generic methodology and model regarding power consumption prediction in manufacturing is required in order to cover the variety of processes, machines and materials. Furthermore, an approach must support flexible levels of granularity for predicting the energy consumption of manufacturing processes. On the one hand, a whole factory may be the object of investigation while, on the other hand, predictions for finer-grained levels, such as certain parts of a machine, are required to allow for specific optimizations. Our contribution is twofold. First, we propose a generic model for the specification of the power-consuming machine. A tree-based compositional approach supports arbitrary levels, depending on the structure of the machine, or external factors, such as company policies. This approach is highly extensible since the models are stored in ontologies. Second, we propose a methodology for static and dynamic modeling of power consumption for every structural level. Based on that model the prediction can be realized. In addition, we provide an example implementation and prediction for a continuous casting machine process.

关键词： Energy efficiency Predictive Model Ontology

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Decision Support for Planning Techniques in Energy Efficiency Projects

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Procedia CIRP 2018年 69卷 306-311页

作者： Marian Süße Johannes Stoldt Andreas Schlegel Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

Factory operators can select from a multitude of measures to improve their energy efficiency. Despite the variety of planning techniques intended to help investigating the energy flows, little assistance is available for determining the most efficient approach to pursue in a specific project. This paper presents decision support procedures for making appropriate selections during planning, focusing on the selections of an energy model and a matching energy data acquisition method. They build on problem-independent decision models and systematize available alternatives. The models are solved independently by applying the Analytic Hierarchy Process that allows the integration and quantification of different criteria.

关键词： Energy efficiency Sustainable development Decision-making Analytic Hierarchy Process

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Smart components by additive technologies

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IOP Conference Series: Materials Science and Engineering 2019年第1期480卷

作者： I Dani Fraunhofer Institute for Machine Tools and Forming Technology Germany

Smart components are key technologies for industry 4.0 as well as the Internet of Things. The application areas include e.g. systems for sustainable production, automotive, smart agriculture, and smart home. In order to integrate intelligence within a component, a sensor or actuator system typically needs to be embedded within the component itself during fabrication. Additive manufacturing has been extended to more and more industries and is now being used not only in toolmaking, but also in the series production of components. Geometric functionalization for conformal cooling is already state of the art in tool making. Despite the great potential of function-integrated parts, publications on sensor integration into parts fabricated by additive manufacturing are still rarely found. First approaches address multimaterial printing by using insulating and conductive materials as well as the integration of smart elements during the printing process. Laser beam melting (LBM) is an additive manufacturing technology for geometrically complex parts based on the layer wise and selective melting of metal powders. As proof-of-concept of the developed integration concept, based on LBM, the functionalization of tools and medical implants will be presented.

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Structural loading of cellular metals: Damage mechanisms and standardization concepts 10th

Structural loading of cellular metals: Damage mechanisms and...

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10th International Conference on Porous Metals and Metallic Foams, MetFoam 2017

作者： Krupp, Ulrich Hipke, Thomas Nesic, Srecko Institute of Materials Design and Structural Integrity University of Applied Sciences Osnabrück Osnabrück49009 Germany Fraunhofer Institute of Machine Tools and Forming Technology IWU Chemnitz09126 Germany

ISBN: (纸本)9783035712315

Structural loading of cellular metals is strongly affected by brittle fracture of cell struts and walls that exhibit tensile loads, e.g., during fatigue loading. The present paper summarizes results of compression, tension and cyclic loading experiments on various closed-cell metal foams and metal foam sandwiches (Alulight, Alporas, Foamtech, AFS) using various mechanical testing systems. The results were correlated with a thorough analysis of the cellular mesostructure and the cell strut/wall microstructure by means of scanning electron microscopy revealing defects, such as casting porosity and large Si precipitates in the Al-Si eutectic of aluminum cast alloy. The results of the work served for the definition of testing standards for compression testing (ISO 13314) and tensile testing (DIN 50099), which are outlined in the paper. Such standards and design guidelines are crucial for a successful implementation of cellular metals in innovative products in mechanical, automotive and energy engineering as well as in bioengineering. © 2018 Trans Tech Publications, Switzerland.

关键词： Tensile testing

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Modified Cross-Wedge Rolling for Creating Hollow Shafts

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Procedia Manufacturing 2018年 21卷 53-59页

作者： Dirk Landgrebe Jürgen Steger Uwe Böhmichen Markus Bergmann Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Reichenhainer Str. 88 09126 Chemnitz Germany

Cross-wedge rolling (CWR) is an incremental forming method for producing rotationally symmetric components such as a basic shape of gear shaft or a preform before impression die forging. In CWR the material of a solid cylindrical billet is redistributed in axial direction while the billet diameter is reduced. Conventional CWR cannot be used to produce hollow shapes. This paper presents a modified CWR process, which enables the manufacturing of hollow shafts and thus provides a technological base for utilizing the large potential of the method regarding cost and resource efficiency in mass production. The method introduces two mandrels which act concurrently with the tooling wedges in an elaborate kinematic system. During processing, the generated shear stresses induce fracturing located along the billet axis. The actively driven mandrels use the fracture and penetrate axially into the workpiece. This paper provides a description of the basic principle of this innovative method and discusses the complex interaction between tool geometries, kinematic system and processing parameters.

关键词： Production Process Hot Forging Cross-wedge Rolling Tubing Billet Preforming

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Sandwich manufacturing with foam core and aluminum face sheets - A new process without rolling 10th

Sandwich manufacturing with foam core and aluminum face shee...

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10th International Conference on Porous Metals and Metallic Foams, MetFoam 2017

作者： Hohlfeld, Jörg Hipke, Thomas Schuller, Friedrich Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 Chemnitz09126 Germany Havel metal foam GmbH Am Suedtor 1 b Brandenburg an der Havel14774 Germany

ISBN: (纸本)9783035712315

The manufacturing processes for sandwiches made with aluminum or steel sheets are differentiated by their various melting ranges. Sandwiches with aluminum face sheets have recently been produced using the so-called AFS technology, which includes a rolling process. However, it is desirable to avoid rolling for cost reduction and allow quick and flexible responses to the customer needs, the manufacturing process needs to be redesigned. This publication introduces a sandwich manufacturing approach that modifies the production of sandwiches with aluminum face sheets. The necessary process steps as well as the test results of foaming and peeling tests are presented. For a successful implementation of the approach it has been demonstrated by a sandwich production with a surface dimension of 1.500 mm x 1.000 mm. © 2018 Trans Tech Publications, Switzerland.

关键词： Cost reduction

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Verification of a novel measuring method for determining pre- and postoperative leg length in the context of total hip arthroplasty: a technical feasibility study

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Journal of Medical Engineering and technology 2018年第8期42卷 588-594页

作者： Schmidt, Michael Prietzel, Torsten Wendler, Toni Möbius, Robert Schleifenbaum, Stefan Hammer, Niels Grunert, Ronny ZESBO - Center for Research on Musculoskeletal Systems University of Leipzig Leipzig Germany Department of Orthopaedic Trauma and Plastic Surgery University of Leipzig Leipzig Germany Department of Orthopaedic and Trauma Surgery HELIOS Clinic Blankenhain Blankenhain Germany Department of Anatomy University of Otago Dunedin New Zealand Fraunhofer Institute for Machine Tools and Forming Technology Fraunhofer IWU Dresden Germany

Following total hip arthroplasty (THA), leg length can easily be modified, for example by different-sized endoprosthetic components. Currently, precise reconstruction depends mainly on the assessment of the surgeon. The aim of this study was to determine the accuracy of a new optical measuring system (OMS) using a novel measuring method capable of determining changes in leg length. Measurements with different investigators on an artificial leg and under clinical conditions were carried out. Measurements under clinical conditions were accomplished with a human body donor before and following prosthetic hip implantation. Furthermore, computed tomography (CT) was used to compare the function and the precision of the OMS relating to established measuring methods. The following results were achieved. The overall mean result of preoperative leg length determination by the OMS was 775.3 ± 5.8 mm (CT: 786.4 mm). The overall mean result of postoperative leg length determination by the OMS was 776.9 ± 10.8 mm (CT: 795.0mm). Measurements carried out showed that the novel measuring method works in principle. However, the viable prototype based on it has a lower accuracy compared to CT-based reference measurements, indicating the necessity of integrating more precise hardware. © 2019, © 2019 Informa UK Limited, trading as Taylor & Francis Group.

关键词： Arthroplasty

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