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

作者： Fritzsche, Rayk Ahrens, Antje Hd. of Grp. Adaptable Assembly Syst. at Fraunhofer Inst. for Mach. Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Scientific Employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

The remarkly high degree of automation within body-in-white production, with high quality requirements and the increasing demand for product-flexible production form a conflict of objectives. The most significant challenges in making the operating resources of body-in-white manufacturing more flexible arise with the the development of model-flexible geometry fixtures, with the geometric and qualitative requirements being most significant in the production of vehicle doors. For the efficient design of model-flexible fixtures specific methods and software tools for part alignment, clamp point grouping and fixture design have been developed. © 2023 Elsevier B.V.. All rights reserved.

关键词： Product design

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Novel method for manufacturing herringbone gears by power skiving 15

Novel method for manufacturing herringbone gears by power sk...

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15th CIRP Conference on Intelligent Computation in Manufacturing Engineering, ICME 2021

作者： Bauer, Ruben Dix, Martin Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenainer Str. 88 Chemnitz09126 Germany

Due to the symmetrical flank configuration, herringbone gears have no resulting axial forces and a smaller tooth width than helical gears. Because of existing manufacturing limitations, currently only double helical gears with wide center space or assembled herringbone gears are applied. In the present work, a novel machining method for herringbone gears by power skiving is presented. For this purpose, tool and technology are designed using a mathematical process model and tested subsequently. It is shown that the process can produce the required geometry with significant improvements on productivity and accuracy. Additionally, the unused center area can be eliminated. © 2022 The Author(s).

关键词： Helical gears

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Computer-based design and development of a fully automated assembly of aircraft doors made of thermoplastic composite material

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Procedia CIRP 2024年 126卷 805-810页

作者： Rayk Fritzsche Erik Jäger Head of group Adaptable assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany Scientific employeeat Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 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.

关键词： process automation aircraft production thermoplastic composite material assembly process virtual simulation manufacturing equipment

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

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Procedia CIRP 2025年 133卷 358-363页

作者： Yuan Jing Guanchen Gong Albrecht Hänel Steffen Ihlenfeldt 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.

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Bioinspired approaches for resource-efficient material flow in production – an innovative actuator concept for peristaltic-based transport

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Procedia CIRP 2024年 125卷 249-254页

作者： Henriette Kunze Marcel Lorenz Scientific employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

In automated material flow, in a wide variety of areas, the primary goal is usually to handle a wide spectrum of components as time- and cost-efficiently as possible. In view of the current and future challenges in industrial production, it is becoming apparent that ecological requirements are becoming increasingly important in automation solutions. For example, in form of resource efficiency, transformability and material efficiency. In this context, especially materials handling technology is subject of various optimization approaches, as no value is added to the part handled. The question: "How does material flow occur in nature?" thus offers biologically inspired approaches to thinking about transport in the industrial sector. This paper first presents a selection of concepts or existing mechanisms that are adaptable in materials- handling technology and have been developed based on a biological model. In the second part of this paper, a new concept is presented that is modeled on peristalsis as a transport mechanism. The approach presented here uses tensegrity-structures for assembly, which are characterized by their high material efficiency and flexibility. The transport movement is achieved by peristaltic typical contraction or relaxation of the respective structure parts.

关键词： tensegrity biotensegrity assembly technologies

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Approach to a GPT-based Early Detection Tool to Evaluate Heterogeneous Data Sources and Identify Reconfiguration Needs of SMEs in the Production Sector 57

Approach to a GPT-based Early Detection Tool to Evaluate Het...

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Jacob, Adrian Achour, Anas Ben Teicher, Uwe Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Pforzheimer Str. 7a Dresden01189 Germany TU Dresden Institute of Mechatronic Engineering Helmholtzstr. 7a Dresden01062 Germany

In the face of a rapidly evolving commercial ecosystem, small and medium-sized enterprises (SMEs) must ensure their process chains are capable of swift reconfiguration to mitigate disruptions from supply chain volatility, regulatory changes, and demand shifts. This study addresses the need for reconfiguration in the context of data-driven opportunities for early identification of reconfiguration needs in SMEs, with a focus on the production sector. We identify a variety of diverse and heterogeneous data sources that are critical for tracking these disruptions, such as public news, economic reports, market analyses, legal documents, and internal corporate records. To make use of these data streams, we propose an innovative early detection tool that employs advanced machine learning techniques and private, locally operated Generative Pretrained Transformers (GPTs). This system is intended to process and analyze the various data formats that SMEs encounter including HTML, PDF and plain text as well as quantitative data. By combining public and company internal data while addressing privacy concerns, the tool aims to provide SMEs with a comprehensive tracking of their commercial environments. The tool also addresses the challenges posed by the limited availability of large datasets within SMEs, which are typically required for effective use of machine learning techniques, allowing for effective operation with smaller datasets. As these technologies continue to advance, their impact across various industries, including legal, manufacturing, and supply chain management, is set to expand significantly. The proposed tool offers SMEs enhanced decision-making, compliance assurance, and the ability to proactively adapt to the unpredictable global business landscape. © 2024 The Authors.

关键词： Chains

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Structure and Validation of a Kinematic Surface Simulation Model for the ultrashort-pulse Direct-Laser-Writing Process

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Procedia CIRP 2025年 133卷 227-232页

作者： Fabian Wieland Eric Gärtner Sebastian Wieland Fraunhofer Institute for Machine Tools and Forming Technology IWU Department Functional Surfaces and Micromanufacturing Reichenhainer Str. 88 Chemnitz 09126 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.

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Case Study of Robot Machining at Different Working Space Locations

Case Study of Robot Machining at Different Working Space Loc...

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MECHATRONIKA International Symposium

作者： Mikuláš Szabari Jan Berhold Jan Vetiška František Bradáč Michal Holub Martin Dix Institute of Production Machines Systems and Robotics Brno University of Technology Brno Czech Republic Cutting Technology Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (数字)9798350394900

ISBN: (纸本)9798350394917

Machining, 3d printing and robot welding require a minimum difference between simulated and real position of robot (TCP) to facilitate high quality surface finish and fulfil dimension and form tolerance. The solution is the absolute robot calibration, which increases positional accuracy. In this paper, a calibrated direct-measuring robot is used to machine the sample part. In the experiment, the sample part is positioned at different location and machined by different machining processes. Then the produced part is measured on a coordinate measuring machine (CMM). The quality of the surface finish, dimensions and geometric tolerances are evaluated. This experiment showed the effect of calibration on the machining process. Based on the obtained results, further activities will be directed in the field of increasing the geometric accuracy of industrial robots.

关键词： Drilling Accuracy Coordinate measuring machines Service robots Robot kinematics Machining Kinematics Surface finishing Robots Surface treatment

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Efficient evaluation of the acoustical behavior of gearboxes with various gear blanks using frequency based substructuring 27

Efficient evaluation of the acoustical behavior of gearboxes...

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27th International Congress on Sound and Vibration, ICSV 2021

作者： Hensel, Eric Bräunig, Jan Troge, Jan Stapf, Tom Drossel, Welf-Guntram Fraunhofer Institute for Machine Tools and Forming Technology Dresden Germany

ISBN: (纸本)9788378807995

In several industrial branches, the acoustical behavior of gearboxes plays a major role. In most cases, the transmission's noise is perceived as an annoying sound, the so-called gear whine with narrow-band spectral components. This tonal noise is caused by the gear mesh and is mainly dependent on the number of teeth as well as the corresponding rotational speed. In combination with the frequency-dependent structure-borne and airborne sound transfer paths of the gearbox and its subsequent systems, different speeds may lead to resonant system response due to the variable excitation frequencies. The purpose within the design process of gearboxes is the identification of such critical acoustic load conditions and the deviation of adequate measures to improve the acoustical behavior. As well known from other applications, the frequency based substructuring provides a methodology to evaluate the vibrations of a system consisting of different subsystems represented by frequency-dependent admittance functions. A main advantage of this method is that the single subsystems are independent from the mounting conditions. Within the present paper, the frequency based substructuring approach is used to evaluate the dynamic behavior of a single-stage gearbox with different gear blanks but equal tooth geometries. After a short introduction of the corresponding theory, the application of the frequency based substructuring method on gearbox dynamics is shown. In a next step, the simulation results are compared to experimental data obtained by test bench measurements with two different types of blanks - a reference model with no modifications as well as a gear with a metal foam core to change the stiffness of the gear blank significantly. Finally, the influences of different gear blanks are shown and discussed based on simulation results. © "Advances in Acoustics, Noise and Vibration - 2021" Proceedings of the 27th International Congress on Sound and Vibration, ICSV 2021. All rights re

关键词： Metals

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Methods for the environmental and economic assessment in early product design – a case study-based overview for wind turbines in urban areas

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Procedia CIRP 2024年 122卷 789-794页

作者： Martin Zumpe Maximilian Stange Ahmet Burak Ertem Marian Süße Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

The assessment of environmental impacts has become an inevitable necessity for many manufacturing companies – not only from a mere retrospective viewpoint but also for product design decisions. At the same time, economic feasibility must be constantly considered throughout all product design phases. For both dimensions, many different decision-support methods exist. However, there is a lack of combined assessment methods especially in early product design phases, when product characteristics, manufacturing technologies and corresponding data are still uncertain. The paper provides an overview and qualitative evaluation of different methods for economic and ecological assessment in product design stages. Based on this, a generalized procedure for combined economic and ecological decision-making during product design is derived, highlighting possible coping mechanisms for uncertain or insufficient data. Both, the evaluation of available assessment methods as well as the derived procedure are transferred to the specific requirements of wind turbines in urban areas. As a result, open research aspects and the next steps for method development are derived.

关键词： Eco-design methodology LCA Evaluation Environment Wind Turbines

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