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14th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2014

作者： Hackert-Oschätzchen, Matthias Martin, André Meichsner, Gunnar Schubert, Andreas Faculty of Mechanical Engineering Technische Universität Chemnitz Chemnitz09107 Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz09126 Germany

ISBN: (纸本)9780956679031

Electrochemical Machining (ECM) is a promising micro-production technique for the creation of complex and highly accurate three-dimensional geometries in electrically conductive materials. As the electrochemical dissolution behavior is independent from the material's mechanical characteristics like hardness and ductility, ECM is an alternative processing technique to create micro-structures even in mechanically hard to machine alloys. The basic principle of ECM is the anodic dissolution of work piece material by electric charge transport. As a special procedure electrochemical machining with continuous electrolytic free jet (Jet-ECM) offers the possibility to machine work pieces at extremely high current densities up to 1000 A/cm2 [1,2]. In Jet-ECM the electrolyte is pumped continuously through a micro nozzle and ejected with an average speed of approximately 20 m/s perpendicularly to the work piece surface. Thus, a free jet is formed on the surrounding atmospheric air, which leads to a high localization of the current density and therefore to a highly localized machining area around the impinging jet. From the previous work on Jet-ECM the working gap was detected as a significant process variable, which needs an adequate control or adjustment. In this study, an analysis of potential strategies to control this variable is summarized.

关键词： Electrolytes

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Integrated Sensors System for Human Safety during Cooperating with Industrial Robots for Handing-over and Assembling Tasks

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Procedia CIRP 2014年 23卷 65-70页

作者： Mohamad Bdiwi Department of Joinging and Assembling Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

Human safety is the main concern which prevents performing some tasks requiring physical interaction between human and robot. Therefore, the safety concept was previously based on eliminating contact between human and robots. This paper will propose a robot system which integrates different types of sensors to ensure human safety during the physical human robot interaction. The implemented sensors are vision, force and sensitive skin. Using vision system, the robot will be able to detect and recognize human face, loadfree human hand and any object carried by human hand (active hand). Furthermore, it will help the robot to define in which directions the force should be applied and what are the dangerous directions for human safety. The force sensor will help the robot to react to the motion of the human hand during the handing-over or assembling task. The sensitive skin will prevent any collision between the human and the robot arm. The proposed system is supported with a voice system for informing human about the actual status of the system.

关键词： Human-robot interaction Human-safety visual servoing force control handing-over and assembly tasks

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Electromagnetic Joining of Hybrid Tubes for Hydroforming

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Procedia CIRP 2014年 23卷 1-6页

作者： Verena Psyk Thomas Lieber Petr Kurka Welf-Guntram Drossel Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 09126 Chemnitz Germany

Joining of functionally adapted and weight-optimized semi-finished parts by electromagnetic compression is investigated taking into account that the resulting component is further processed by hydroforming. For this purpose both ends of an aluminum tube are connected to steel tubes. During the subsequent hydroforming of the hybrid tube the joints are exposed to extreme loading. Finite-Element-Simulation is applied for characterizing and quantifying these loads. The electromagnetic joining process is analyzed, the joints are characterized by microstructural analysis and the resulting properties of the joint are evaluated by model experiments.

关键词： Electromagnetic forming joining hydroforming

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Tempered forming of Magnesium Alloys Using the Example of Roll forming

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Materials Today: Proceedings 2015年 2卷 S60-S66页

作者： K. Richter R. Haase F. Schieck D. Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

The sheet metal forming of magnesium alloys requires an adaption of the forming processes utilized. Due to limited formability at room temperature, heating above a temperature of 200 to 225 °C is necessary in order to activate additional gliding planes. By the example of roll forming, the temperature regime and implementation of heating equipment into the forming process is illustrated. On account of the progressive feed of sheet material necessary for roll forming, a transverse flux induction heating was used in the experimental setup. Results of experimental design and experimentation with AZ31 alloy will be presented in this paper.

关键词： Magnesium Alloys AZ31 Roll forming Inductive Heating

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Serial Production of Cellular Structures – No Additives Allowed!

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Procedia Materials Science 2014年 4卷 57-62页

作者： Christian Hannemann Steffen Scholz Department of Lightweight Design Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 09126 Chemnitz Germany

As reported before, the Lightweight design department of the fraunhofer Institute IWU is collaborating with several foundries in manifold projects. The objectives show a large variety starting with energy management activities and leading to product and technology development. Especially in high pressure die casting, most of the products are material minimized till the edge of the castability. The wall thickness is decreased to their very limits, holes are integrated for lightweight reasons and structures modified by topology optimization pushing this traditional industrial sector to the newest state of technology. Many attempts have been published trying to combine that high level serial production technology with the cellular structures for lightweight reasons on the one hand and for material efficiency on the other. Anyway, till now none of them is dealing with real serial die casting parts. The geometry of the parts needs to be adapted to the requirements of the pore generation procedure. As these approaches are rather complex, in some cases the invested energy, time and additives consume the savings reached by the pore integration. The intention of the project is based upon the omnipresent resource efficiency. By intensive technological investigation of the state of the art and several practical test runs, almost all published strategies of pore generation in high pressure die casting have been analyzed. The industrial partner of the project rejected all of the current approaches as irrelevant for serial application forcing us to create new ideas. Differing from common metal foam structures the objected material savings are around 20-25%. By changing the die-casting-machine setup and several parameters the first parts in original geometry have been realized reaching the target of material reduction. Mostly homogenous pores have been integrated in common serial parts containing a wall thickness of below 3 mm while the outer shell is still completely closed and

关键词： High-pressure-die-casting defined porosity castings resource efficiency serial production

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On the development of an intrinsic hybrid composite

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IOP Conference Series: Materials Science and Engineering 2016年第1期118卷

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 Faculty of Mechanical Engineering Technische Universität Chemnitz D-09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology D-09126 Chemnitz Germany Professorship of Materials and Surface Engineering Institute of Materials Science and Engineering Technische Universität Chemnitz D-09125 Chemnitz Germany Chair of Materials Science Institute of Materials Science and Engineering Technische Universität Chemnitz D-09125 Chemnitz Germany

Hybrid parts, which combine low weight with high strength, are moving into the focus of the automotive industry, due to their high potential for usage in the field of crash-relevant structures. In this contribution, the development of an intrinsic hybrid composite is presented, with a focus on the manufacturing process, complex simulations of the material behaviour and material testing. The hybrid composite is made up of a continuous fibre- reinforced plastic (FRP), in which a metallic insert is integrated. The mechanical behaviour of the individual components is characterised. For material modelling, an approach is pointed out that enables modelling at large strains by directly connected rheological elements. The connection between the FRP and the metallic insert is realised by a combination of form fit and adhesive bonds. On the one hand, adhesive bonds are generated within a sol gel process. On the other hand, local form elements of the metallic insert are pressed into the FRP. We show how these form elements are generated during the macroscopic forming process. In addition, the applied sol gel process is explained. Finally, we consider design concepts for a specimen type for high strain testing of the resulting interfaces.

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Functionally Aluminum Foam Composites for Building Industry

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Procedia Materials Science 2014年 4卷 133-138页

作者： Thomas Hipke Jörg Hohlfeld Susi Rybandt Department of Lightweight Design Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany

Aluminum foams already are in automotive and machine tool industry serial application. Only little interest has been shown by the construction or building industry so far. The still relatively high material costs, lack of connecting and joining techniques, as well as reservations of the users towards new material solutions are the reasons why. In the building industry design for efficiency is taking into account the principles of lightweight material and structure. Especially sandwich panels with aluminum foam core are of high interest. The high rigidity with low weight and high resistance to fire are the major advantages of these panels. Also these semi-finished materials shield electromagnetic waves and show extensive vibration reduction and sound insulation. Combining the sandwiches with additional functions such as cooling and heating by integrated tubes is one example.

关键词： Aluminum foam Foam composites Semi-finished parts Foam sandwiches Building industry Building halls.

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Jet-Electrochemical machining of selective laser melted aluminum and steel alloys for micro injection moulds 14

Jet-Electrochemical machining of selective laser melted alum...

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14th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2014

作者： Schubert, Andreas Zeidler, Henning Martin, André Hackert-Oschätzchen, Matthias Kempen, Karolien Kruth, Jean-Pierre Faculty of Mechanical Engineering Technische Universität Chemnitz Chemnitz09107 Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz09126 Germany Department of Mechanical Engineering Celestijnenlaan 300 Leuven3001 Belgium

ISBN: (纸本)9780956679031

For a flexible and resource efficient generation of moulds for micro-injection moulding, additive manufacturing processes such as Selective Laser Melting are used. Electrochemical machining (ECM) is a promising technique for the final shaping of the mould and for creation of the injection cavity with required precision, since ECM is independent of material hardness and ductility [1]. The latter property is important concerning SLM produced moulds, which are often harder and stronger than cast moulds [2]. In this study, electrochemical machining of two SLM materials, AlSi10Mg Aluminium alloy and 18Ni-300 Nickel-based maraging tool steel, is analysed. A unique process applying a continuous electrolytic free jet (Jet-ECM) is used that offers the possibility to generate micro-structures by controlling the nozzle movement and the current flow [3].

关键词： Aluminum alloys

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Mobile Augmented Reality Based Monitoring of Assembly Lines

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Procedia CIRP 2014年 23卷 246-251页

作者： Christian Kollatsch Marco Schumann Philipp Klimant Volker Wittstock Matthias Putz Institute for Machine Tools and Production Processes Technische Universität Chemnitz Reichenhainer Straße 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany

Showing process-relevant information of assembly lines is an important task in production, e.g. for diagnostic purposes. Accessing the relevant manufacturing values during production requires extensive knowledge of the used machines and their control systems (e.g. PLC, CNC) and could cause a delay of the production process. Therefore, this paper presents an Augmented Reality (AR) based application for mobile devices realizing a user-friendly and problem-oriented visualization of relevant information directly on-site. The AR application uses a uniform graphical user interface. Due to this the user does not need to handle different human machine interfaces.

关键词： Augmented Reality Assembly Monitoring

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Microstructuring of Surfaces by Two-stage Vibration-assisted Turning

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Procedia CIRP 2014年 14卷 136-141页

作者： R. Zhang P. Steinert A. Schubert Technische Universität Chemnitz Faculty of Mechanical Engineering Professorship Micromanufacturing Technology 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany

Microstructuring is one suitable method to improve the tribological properties of surfaces. It leads to a reduction in friction and wear, especially in highly loaded tribological contacts. There are several machining techniques to generate microstructures, such as laser beam removal, cold forming, etching or fly-cutting. This paper describes a new method to produce microstructured surfaces more economically, based on a two- staged vibration-assisted turning process. During the first step, a specific microstructure is realized by ultrasonic vibration assistance of the turning tool in the direction perpendicular to the workpiece surface. In the subsequent step, the peaks of the obtained microstructured surface are removed by precision turning without vibration. This results in a plateau-shaped and microdimpled surface. The two-staged vibration- assisted turning process offers the advantage that no additional process is required after finishing because the microstructuring process is already part of the finishing operation. The investigated process can easily be integrated into large batch production, e. g., for tribological optimization of powertrain components.

关键词： Surface microstucturing Vibration-assisted turning Tribology

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