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Simulation-based Correction Approach for Thermo-elastic Workpiece Deformations During Milling Processes

Procedia CIRP 2016年 46卷 103-106页

作者： J. Glänzel R. Herzog S. Ihlenfeldt A. Meyer R. Unger Fraunhofer Institut for Machine Tools and Forming Technology IWU Chemnitz Germany Technische Universität Chemnitz Chemnitz Germany Technische Universität Dresden Dresden Germany

Based on the method of adaptive finite elements (FEM) a correction approach has been considered to identify the influence of thermo-elastic workpiece deformations during the production process milling. The paper presents a simulation-based tolerance variation calculation of cutting paths, which is caused by the heat input of the machine tool. Therefore a mathematical method is developed to numerically depict the progress of the miller with different curves A(t), B(t) and C(t). These curves are used to map the state of the milling path during the production process as well as to compare the current workpiece contour and the target workpiece contour. The tool center point (TCP) correction results from mapping of time-dependent deformation fields from the FE simulation. The aim is, on the one hand, to make statements before the production about keeping the tolerance, and on the other hand, to derive other correction approaches for the adaption of the cutting path coordinates.

关键词： milling tolerancing material removal thermo-elastic adaptive FEM

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Process Monitoring of Abrasive Waterjet Formation

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Procedia CIRP 2016年 46卷 43-46页

作者： M. Putz M. Dittrich M. Dix Technische Universität Chemnitz Institute for Machine Tools and Production Processes (IWP) Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

Difficult to machine materials require innovative processing solutions for a stable and high quality contouring process of complex forms. Abrasive waterjet cutting gains in importance due to the continuous development of novel high performance materials and multi-material components. A reliable process monitoring during the machining operation becomes essential to avoid waste production. However, the measurement of the process conditions during abrasive waterjet cutting is difficult based on the rough environment inside the machining zone. In this paper appropriate methods for in-process monitoring of the jet conditions, in particular the critical nozzle wear as well as other process output parameters are being tested, discussed and classified.

关键词： Waterjet machining In-process measurement Monitoring

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Agile Engineering in Mechatronic Education Interdisciplinary Development of a Mechatronic System using Scrum

Agile Engineering in Mechatronic Education Interdisciplinary...

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Europe-Asia Congress on Mechatronics

作者： Thorsten P. Klein Benny Drescher Gunther Reinhart Project Group Resource-efficient Mechatronic Processing Machines (RMV) Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Beim Glaspalast 5 86153 Augsburg Thorsten Project Group Resource-efficient Mechatronic Processing Machines (RMV) Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Beim Glaspalast 5 86153 Augsburg

ISBN: (纸本)9781509017881

Agile procedures (e.g. Scrum) are applied in software engineering increasingly. These procedures enhance interdisciplinary collaboration, improvements of lead times and reduction of development costs. Hence, latest research activities are transferring such flexible techniques into machinery and plant construction, in order to cope with the rising software integration into mechatronic modules. As agile procedures have been omitted in mechanical engineering yet, we introduce a novel concept of a learning platform about Agile Engineering. This paper presents the background and experiences of Agile Engineering as well as the setting, the results and first educational achievements within our academic courses.

关键词： Agility Scrum Mechatronics Lean Product Development Development Process Learning Platform

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Faster temperature control systems for hot embossing and injection molding 15

Faster temperature control systems for hot embossing and inj...

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15th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2015

作者： Edelmann, Jan Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (纸本)9780956679079

Research work aims to develop a fast, production suitable hot embossing technology including appropriate tool systems for low-cost and production-integrated manufacturing of high-precision microfluidic structures in polymer films. The implementation is demonstrated by structuring of microfluidic films for disposable diagnostic devices used in home-care and point-of-care applications. The approach focuses on the development and thermal design of a tool system for fast hot embossing on basis of a fast non isothermal process. Close contour tempering of the active parts is the core of this approach. Based on an industrial specification the paper will describe tempering strategy, design and simulation of the tool concept. Heat flux and heat capacities together with the power loss in the system are used for calculating the tempering cycle. Based on that, the setup of an optimized tool system consisting of heating elements and a refrigerant system is presented. The new tool concept is thermally characterized by thermocouple and infrared measurements. Furthermore the system was tested in a commercial hot embossing equipment to demonstrate the improvements. It could be shown that a cycle time between one and two minutes is possible, in comparison to cycle times of fifteen minutes in conventional hot embossing systems. Although the test system was not optimized so far, in the embossing tests all items were replicated correctly and the microfluidic function was ensured. The results of the research work are applicable also for the optimization of injection molding tool systems.

关键词： Microfluidics

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Investigation of Cooling and Lubrication Strategies for Machining High-temperature Alloys

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Procedia CIRP 2016年 41卷 835-840页

作者： Katja Busch Carsten Hochmuth Bernhard Pause Andrea Stoll Rafael Wertheim Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany NILES – SIMMONS Industrieanlagen GmbH Zwickauer Straße 355 09117 Chemnitz Germany

Optimal and efficient machining of high-temperature alloys is one of the main goals set by the manufacturing technology today, taking into account the unique properties of these materials, the required performance and the process parameters. One of the most important parameters investigated and presented in this paper is the optimal cooling and lubrication strategy. The application of various hybrid cooling strategies such as high-pressure cooling, cryogenic cooling and aerosol dry lubrication offers the potential to extend profitability and energy efficiency as well as high performance and improved surface integrity. The paper introduces fundamental functions, cooling systems and relationships that characterize the efficient utilization on standard machine tools. Based on fundamental investigations conducted using high-temperature alloys with poor machinability such as Titanium alloy Ti6Al4 V and Inconel 718, relevant influencing parameters are derived and optimization options are presented for the cooling strategies.

关键词： Turning cryogenic machining high-pressure cooling

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Fast Determination of the Material Removal Characteristics in Pulsed Electrochemical Machining

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Procedia CIRP 2016年 46卷 123-126页

作者： G. Meichsner M. Hackert-Oschätzchen M. Krönert J. Edelmann A. Schubert M. Putz Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 09126 Chemnitz Germany Professorship Micromanufacturing Technology Faculty of Mechanical Engineering Technische Universität Chemnitz 09107 Chemnitz Germany

Electrochemical machining (ECM) of metallic materials is a complex manufacturing process. Currently the design of the process parameters and the cathode geometry is determined by expensive and inefficient experiments. This paper introduces a method for a fast determination of the material removal characteristics in pulsed electrochemical machining (PECM). The determination is performed by help of removal experiments using a PEMCenter 8000. As example the material removal characteristics of stainless steel 1.4301 under PECM conditions are shown. Based on the resulting mathematical description of the material removal characteristics a design of PECM processes by analytical calculations or multiphysics simulation is feasible.

关键词： electrochemical machining precise electrochemical machining localized anodic dissolution material removal characteristics

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Characteristic Diagram Based Correction Algorithms for the Thermo-elastic Deformation of machine tools

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Procedia CIRP 2016年 41卷 801-805页

作者： Christian Naumann Ilka Riedel Steffen Ihlenfeldt Ulrich Priber Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Chemnitz University of Technology Department of Mathematics Reichenhainer Straße 41 09126 Chemnitz Germany

This paper presents a characteristic diagram based approach to the correction of thermally induced tool center point displacements of machine tools. The entire process from the introduction of the correction principle to the issues arising in the online capable application of this correction method will be discussed, with special focus on the improvement and optimization of the calculation, input selection and grid structures of the characteristic diagrams.

关键词： Thermal error machine tool Correction Tool center point Regression Temperature field Characteristic diagram Smoothed Grid Regression

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Granulation of Extruded Plastic Wires – Influence of Tool Geometry and Process Parameters

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Procedia CIRP 2016年 46卷 135-138页

作者： Macario Cardone Matthias Putz Gerhard Schmidt Martin Dix Jürgen Friedrich Erich Stockmann Institute for Machine Tools and Production Processes Chemnitz University of Technology 09010 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany Gebr. Saacke GmbH & Co. KG 75181 Pforzheim Germany Reduction Engineering GmbH 70825 Korntal-Münchingen Germany

Granulators cut extruded elastomer wires in small pieces, which can be used as starting raw material for injection molding. This contribution investigates the most relevant parameters of process and tool geometry for the granulation technology, with the aim of improving process efficiency and granule quality. Fiber-reinforced PA and ABS plastics have been analyzed using a dedicated test bench and finite element simulations. High-speed camera and various sensors were used to investigate the cutting process. The considered geometrical and kinematic parameters have been varied within a broad range in order to determine optimum values.

关键词： Cutting tool Fiber reinforced plastic (FRP) Finite Element Method (FEM) Granulation

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Target Systems and Decision-making to Increase Production Sustainability

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Procedia CIRP 2016年 48卷 34-39页

作者： Matthias Putz Uwe Götze Johannes Stoldt Enrico Franz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Chair of Management Accounting and Control Technische Universität Chemnitz Professur BWL III 09107 Chemnitz Germany

Many industrial companies are trying to improve their operation's sustainability. However, these efforts towards change are usually governed by economic considerations. This serves to neglect or at least diminish the perceivable relevance of ecologic or social consequences for investigated alternatives. This paper discusses the implications of multi-criterial target systems which extend the scope of considerations beyond economics to support the realisation of proactive environmental strategies. A special focus is set on the definition of targets as well as decision-making in brown-field planning projects. The findings are applied in a simulation-based study on the parameterisation of an energy-sensitive production control strategy.

关键词： Target systems Brown-field planning projects Sustainability Energy-sensitive production strategy Multi-objective genetic algorithm NSGA-II

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Improving Performance of Turn-milling by Controlling Forces and Thermally Induced Tool-center Point (TCP) Displacement

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Procedia CIRP 2016年 40卷 481-485页

作者： M. Putz S. Ihlenfeldt U. Karaguzel U. Semmler E. Budak M. Bakkal R. Wertheim Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany Mechanical Engineering Department Istanbul Technical University 34437 Istanbul Turkey Faculty of Engineering and Natural Sciences Sabanci University 81474 Istanbul Turkey

Improving performance during fine turn-milling operations including accuracy and productivity requires controlling of the cutting forces and the thermally induced displacement of the cutting edge. The objective of this investigation is to determine the thermally induced displacement of TCP during turn-milling and to reduce this displacement by using pressurized cooled air. The forces and tool elongation simulated by FEM are compared to measured values. It was shown that the amount of tool elongation could be 40% of the depth of cut in fine turn-milling, and it is possible to predict the tool elongation by FEM. Furthermore, cooled air can reduce the tool elongation by 65%.

关键词： Thermal effects Machining Finite Element Method (FEM)

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