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Energy-efficiency in a Hybrid Process of Sheet Metal forming and Polymer Injection Moulding

Procedia CIRP 2016年 40卷 109-114页

作者： D. Landgrebe V. Kräusel A. Rautenstrauch A. Albert R. Wertheim Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany Institute for Machine Tools and Forming Technology Technische Universität Chemnitz Reichenhainer Straße 70 09126 Chemnitz Germany

Hybrid processes are an efficient solution for shortening process chains and improving performance. As an example a process combination of sheet metal forming and polymer injection molding is introduced and investigated. The merging of forming and moulding processes into a single step process allows generating potential cost-savings, especially for medium to large production volumes. Based on the technological comparison between the conventional and the new process chain, the determination of the energy consumption and the detected impacts concerning the process efficiency are presented, showing that approx. 20% less energy is required due to using only one tempered tooling and reduction of handling operation.

关键词： forming Energy Efficiency Polymer Moulding Hybrid process

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Task-based Motion Control of Digital Humans for Industrial Applications

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Procedia CIRP 2017年 62卷 535-540页

作者： Luigi Pelliccia Franziska Klimant Agostino De Santis Giuseppe Di Gironimo Antonio Lanzotti Andrea Tarallo Matthias Putz Philipp Klimant Institute for Machine Tools and Production Processes Technische Universität Chemnitz Reichenhainer Str. 70 09126 Chemnitz Germany PRISMA Lab DIETI Università degli studi di Napoli Federico II Via Claudio 21 80125 Napoli Italy Joint Lab IDEAS DII Università degli studi di Napoli Federico II P.le Tecchio 80 80125 Napoli Italy Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Reichenhainer Str. 88 09126 Chemnitz Germany

Nowadays digital substitutes of human beings (digital humans), capable of interacting with digital mock-ups in Virtual Reality, are widely used in many fields of engineering (e.g. ergonomics, product design, maintenance, and training). Nevertheless, the animation process of digital humans is still a time-consuming task, and its accuracy and reliability strongly depend on the experience and the skills of the operator. This paper presents an innovative algorithm capable of significantly speeding up the animation process of digital humans, allowing the operator to focus only on the so-called “task-related control points”. This approach allows also to easily conduct biomechanical analyses. The algorithm has been tested with reference to several application scenarios in Virtual Reality.

关键词： Virtual reality Algorithm Kinematics Digital humans

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Intrinsic manufacture and design of positive locking fibre reinforced thermoplastic metal hollow structures 17

Intrinsic manufacture and design of positive locking fibre r...

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17th European Conference on Composite Materials, ECCM 2016

作者： Barfuss, D. Grützner, R. Garthaus, C. Gude, M. Institute of Lightweight Engineering and Polymer Technology Technische Universität Dresden Holbeinstr. 3 Dresden01307 Germany Fraunhofer-Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 Chemnitz09126 Germany

ISBN: (纸本)9783000533877

In contrast to common and classical joining technologies for composite metal hybrid structures such as bonding and riveting, profile and contour joints offer promising potential for novel lightweight structures. First and foremost, joining systems with a form closure function enable to pass very high loads into rod- and tube-shaped fibre reinforced structures, whereby a high degree of material utilization for composite parts can be achieved. This paper presents an intrinsic manufacturing approach for the efficient production of carbon fibre reinforced thermoplastic hollow composite structures with multi scale structured metallic load introduction elements. © 2016, European Conference on Composite Materials, ECCM. All rights reserved.

关键词： Manufacture

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Process simulation and experimental validation of Hot Metal Gas forming with new press hardening steels

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Journal of Physics: Conference Series 2017年第1期896卷

作者： A. Paul F. Reuther S. Neumann A. Albert D. Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology (Fraunhofer IWU) Reichenhainer Straße 88 09126 Chemnitz Germany

One field in the work of the fraunhofer Institute for machine tools and forming technology IWU in Chemnitz is industry applied research in Hot Metal Gas forming, combined with press hardening in one process step. In this paper the results of investigations on new press hardening steels from SSAB AB (Docol®1800 Bor and Docol®2000 Bor) are presented. Hot tensile tests recorded by the project partner (University of West Bohemia, Faculty of Mechanical Engineering) were used to create a material model for thermo-mechanical forming simulations. For this purpose the provided raw data were converted into flow curve approximations of the real stress-real strain-curves for both materials and afterwards integrated in a LS-DYNA simulation model of Hot Metal Gas forming with all relevant boundary conditions and sub-stages. Preliminary experimental tests were carried out using a tool at room temperature to permit evaluation of the forming behaviour of Docol 1800 Bor and Docol 2000 Bor tubes as well as validation of the simulation model. Using this demonstrator geometry (outer diameter 57 mm, tube length 300 mm, wall thickness 1.5 mm), the intention was to perform a series of tests with different furnace temperatures (from 870 °C to 1035 °C), maximum internal pressures (up to 67 MPa) and pressure build-up rates (up to 40 MPa/s) to evaluate the formability of Docol 1800 Bor and Docol 2000 Bor. Selected demonstrator parts produced in that way were subsequently analysed by wall thickness and hardness measurements. The tests were carried out using the completely modernized Dunkes/AP&T HS3-1500 hydroforming press at the fraunhofer IWU. In summary, creating a consistent simulation model with all relevant sub-stages was successfully established in LS-DYNA. The computation results show a high correlation with the experimental data regarding the thinning behaviour. The Hot Metal Gas forming of the demonstrator geometry was successfully established as well. Different hardness values could b

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Adaptronic Applications in Cutting machines

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Procedia CIRP 2016年 46卷 303-306页

作者： W.-G. Drossel A. Bucht K. Pagel T. Mäder T. Junker Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

Adaptronic systems are able to improve high performance cutting technologies making them more stable, economic and efficient leading to a higher product quality. The main objectives of adaptronic systems in production technologies, beyond controlling process parameters, are either reducing vibration or generating them. The latter topic is a highly innovative area of research since it offers alternative approaches to improve product quality and optimize machining processes regarding efficiency and economy. Current research at fraunhofer Institute for machine tools and forming technology IWU focuses on facilitating the transfer of scientific knowledge to industrial solutions. Therefore, possible reasons preventing industrial application of adaptronic systems in cutting machines are identified and initial ideas to overcome these problems are presented.

关键词： machine tool Adaptive control Vibration assisted machining

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Manufacturing of hybrid aluminum copper joints by electromagnetic pulse welding – Identification of quantitative process windows

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AIP Conference Proceedings 2017年第1期1896卷

作者： Verena Psyk Christian Scheffler Maik Linnemann Dirk Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology – IWU Reichenhainer Strasse 88 09126 Chemnitz Germany

Compared to conventional joining techniques, electromagnetic pulse welding offers important advantages especially when it comes to dissimilar material connections as e.g. copper aluminum welds. However, due to missing guidelines and tools for process design, the process has not been widely implemented in industrial production, yet. In order to contribute to overcoming this obstacle, a combined numerical and experimental process analysis for electromagnetic pulse welding of Cu-DHP and EN AW-1050 was carried out and the results were consolidated in a quantitative collision parameter based process window.

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The Interface of an Intrinsic Hybrid Composite – Development, Production and Characterisation

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Procedia CIRP 2017年 66卷 289-293页

作者： R. Kießling J. Ihlemann M. Riemer W.-G. Drossel I. Scharf T. Lampke S. Sharafiev M. Pouya M.F.-X. Wagner Professorship of Solid Mechanics Chemnitz University of Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Reichenhainer Str. 88 09126 Chemnitz Germany Professorship of Materials and Surface Engineering Chemnitz University of Technology Erfenschlager Str. 73 09125 Chemnitz Germany Professorship of Material Science Chemnitz University of Technology Erfenschlager Str. 73 09125 Chemnitz Germany

Due to a combination of different classes of materials, intrinsic hybrid composites are characterised by high strength and low weight. The mechanical properties of hybrid parts are mainly determined by the interface between the different materials. Consequently, this interface has to be considered in detail within the development of an intrinsic hybrid composite. The general approach of the considered composite is the combination of a mechanical form fit with adhesive bonding. This contribution focuses on the development, production and characterisation of the interface between aluminium and a fibre reinforced polymer as well as of the hybrid composite.

关键词： hybrid composite interface mechanical interlocking cohesive bonding crash performance

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Manufacturing of high added value titanium components. A South African perspective

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IOP Conference Series: Materials Science and Engineering 2018年第1期430卷

作者： D Dimitrov E Uheida G Oosthuizen D Blaine R Laubscher A Sterzing P Blau W Gerber O F R A Damm Department of Industrial Engineering Faculty of Engineering Stellenbosch University South Africa Department of Mechanical and Mechatronic Engineering Faculty of Engineering Stellenbosch University South Africa Department of Mechanical Engineering University of Johannesburg South Africa Fraunhofer Institute for Machine Tools and Forming Technology Germany Aerosud Aviation South Africa

South Africa has significant titanium reserves and is developing strategies to not only provide this raw material on global markets, but to manufacture complex titanium alloy products and participate fully in global supply chains. Pursuing more sustainable process chains, manufacturers are constantly striving to enhance the resource efficiency of their high added value processes. Titanium alloys are used comprehensively in aerospace and biomedical applications, due to its favourable strength-to-weight ratio, corrosion resistance and biocompatibility. These properties, however, contribute to the manufacturing challenges, classifying it as a difficult-to-machine material. Various input factors affect the efficiency of a hybrid process chain. The objectives of this multidisciplinary research group were to demonstrate the reduction of material wastage by up to 50% and machining time up to 20% for selected titanium components. The results clearly demonstrate the ability to increase the technology readiness levels of the selected components and to develop competitive hybrid titanium process chains that will enable South Africa to integrate more into global manufacturing value chains.

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Investigation of the Time-invariance and Causality of a machine Tool for Performing Operational Modal Analysis

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Procedia CIRP 2016年 46卷 400-403页

作者： Matthias Putz Volker Wittstock Martin Kolouch Jan Berthold Technische Universität Chemnitz Professorship for Machine Tools and Forming Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Reichenhainer Str. 88 09126 Chemnitz Germany

The dynamic behaviour of machine tools affects the work-piece quality and productivity. Generally, the difference between the dynamic properties at standstill and during machining is neglected by the commonly applied assessment methods for production systems. Operational modal analysis takes into account these cutting- and operation-dependent influences. However, operation conditions might cause violation of the common measurement assumptions regarding time-invariance and causality. The investigations consider the time-invariance by the measurement of frequency response functions over the working space including the evaluation of mode shapes. The causality is evaluated by dynamic measurements at TCP excited by feed motions.

关键词： machine tool Dynamics Operational modal analysis

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Application of Substructure Decoupling Techniques to Predict Mobile machine Tool Dynamics: Numerical Investigations

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Procedia CIRP 2016年 46卷 537-540页

作者： Mohit Law Hendrik Rentzsch Steffen Ihlenfeldt Matthias Putz Indian Institute of Technology Kanpur India Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz 09126 Germany Institute of Machine Tools and Control Engineering Technische Universität Dresden Germany

In situ machining of large workpieces is made possible by moving mobile machines to workpiece locations. To guide and enhance on site machining performance, dynamics of the assembled system must be predicted beforehand. Beforehand prediction of assembled response requires dynamics of the mobile machine in its free-free configuration be coupled with response of base/workpiece measured at location. Since obtaining the free-free response of the machine is non-trivial, this paper presents a substructure decoupling scheme that instead extracts the machine's response from known dynamics of the machine mounted on a base, and from information of a substructural base system. Simulation driven investigations show the decoupling scheme to be robust even under the vagaries of measurement noise and changes in the residual substructural base system. Extracted dynamics of the machine can be subsequently synthesized with known dynamics of other bases/workpieces for a priori prediction of assembled dynamics to guide first-time-right on site machining.

关键词： Dynamics machine tool Simulation Mobile machine Substructure decoupling

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