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Novel method for manufacturing herringbone gears by power skiving

Procedia CIRP 2022年 112卷 310-315页

作者： Ruben Bauer Martin Dix Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenainer Str. 88 09126 Chemnitz 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.

关键词： herringbone gears power skiving gear machining process model planetary gears

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A New Paradigm in Surface Reconstruction: LTP Features from Surface Images for Inverse Process Modeling

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Procedia CIRP 2025年 134卷 975-980页

作者： Mei Yun Liu Thomas Wiener Martin Dix Professorship Production Systems and Processes Chemnitz University of Technology Straße der Nationen 62 09111 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

This study explores the adaptation of Local Ternary Patterns (LTP) for surface reconstruction, extending its use beyond traditional texture analysis. A systematic methodology, including patch optimization, parameter optimization, and feature selection, is proposed to extract surface-relevant features from images. Applied to spark-eroded surfaces, LTP enables differentiation of surface structures, with slightly reduced classification performance for surfaces with very fine or very coarse roughness. Despite this, the method demonstrates high potential for inverse process modeling, offering a cost-effective alternative for correlating manufacturing parameters with surface characteristics, contributing to improved process optimization and quality control in precision manufacturing.

关键词： Inverse Process Model Local Ternary Patterns (LTP) Surface Reconstruction Electrical discharge machining (EDM)

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The Impact of Post-Processing Heat Treatment on the Magnetic Properties of Additively Manufactured Nd-Fe-B Magnets

SSRN

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SSRN 2024年

作者： Bittner, Florian Kumar Putta, Akhil Juerries, Florian Woodcock, Thomas George Drossel, Welf-Guntram Thielsch, Juliane Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Leibniz IFW Dresden Institute for Metallic Materials Dresden Germany Chemnitz University of Technology Institute for Machine Tools and Production Processes IWP Chemnitz Germany

The effect of post-process heat treatment on microstructure and magnetic properties by laser powder bed fusion (LPBF) additively manufactured Nd-Fe-B magnets was studied in dependence of heat treatment temperature and as built condition. The microstructure of the magnets in the as built condition is partly amorphous. The volume fraction of the amorphous phase depends on the LPBF manufacturing parameters of the magnets, and a subsequent heat treatment above 550°C leads to its crystallization with a corresponding, remarkable improvement in the magnetic properties. Higher heat treatment temperatures allow the precipitation of a-Fe in the microstructure, which deteriorates coercivity but increases remanence. Magnets with high initial volume fraction of amorphous constituents require higher heat treatment temperatures to obtain optimal magnetic performance and show an increased stability against overaging. © 2024, The Authors. All rights reserved.

关键词： Magnetic properties

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Development of general data-based process models for self-pierce riveting 24

Development of general data-based process models for self-pi...

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24th International ESAFORM Conference on Material forming, ESAFORM 2021

作者： Jäckel, Mathias Falk, Tobias Kropp, Thomas Drossel, Welf-Guntram Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany

ISBN: (纸本)9782870193020

The determination of ideal process parameters for mechanical joining processes such as self-pierce riveting currently requires a comprehensive understanding of the process, the availability of the materials to be joined and the corresponding system technology. General process models can simplify the use of these joining technologies, accelerate development cycles and thereby reduce the effort for implementation into production. In this paper, the development of general data-based process models for the mechanical joining method self-pierce riveting with semi-tubular rivet is described. Extensive experimental and numerical investigations with more than 2300 joint combinations for steel and aluminum sheets with tensile strengths between 240 - 1020 MPa were generated for the building of the models. Based on these results, different meta-models are fused into general data-based process models for the self-pierce riveting process in order to show the general relationships between material properties, process parameters and joining results. The paper discusses the acquisition of the experimental and numerical data, the statistical methods for evaluation and the application of the data-based process models. © ESAFORM 2021 - 24th Inter. Conf. on Mat. forming. All rights reserved.

关键词： Riveting

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UV-Imprint of micro-textured polymer films for biomedical disposables 22

UV-Imprint of micro-textured polymer films for biomedical di...

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22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022

作者： Gärtner, Eric Edelmann, Jan Hackl, Claudia Roussak, Liudmila Tomasova, Lea Guttenberg, Zeno Gnüchtel, Sebastian Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Leipzig Germany SensLab GmbH Leipzig Germany Ibidi GmbH Gräfelfing Germany WESKO GmbH Stollberg Germany

ISBN: (纸本)9781998999118

In the life science sector, increasing demands on the reproducibility and accuracy of lab-on-chip systems require new manufacturing technologies for the production of polymer films with multifunctional surfaces. A mass-production capable and cost-effective way to pattern microfluidic films is the manufacturing process of UV injection molding. Therefore, the aim of the project is to develop microstructured polymer films with multifunctional surface properties by means of an injection molding UV plate-to-plate (P2P) replication process. For this purpose, a special film injection molding system was developed that allows filling with different formulations, curing by UV light and molding of the required microstructures. In respect to the application of the microstructured polyacrylate films in cell-based assays as well as biosensor disposables, microstructures of various geometries were designed and produced in the P2P process. In addition, cell tests were performed in this study in order to evaluate the biocompatibility and optical quality of the substrates, and to verify the functionality of the microstructures. Here, we show that the structured polyacrylate foil is a suitable substrate that can be implemented in plastic microfluidic chips for cell-based assays and biosensor disposables. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Polymer films

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Robotic Visual Servoing for Tracking Structureless Moving Parts

Robotic Visual Servoing for Tracking Structureless Moving Pa...

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Iberian Robotics Conference (ROBOT)

作者： Christian Schroder Marco Schumann Rico Loser Philipp Klimant Martin Dix Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Professorship Virtual Technologies Hochschule Mittweida - University of Applied Sciences Mittweida Germany Institute for Machine Tools and Production Processes Chemnitz University of Technology Chemnitz Germany

ISBN: (数字)9798350376364

ISBN: (纸本)9798350376371

The European Union has committed to achieving the 1.5-degree Celsius limit set by the Paris Climate Agreement, emphasizing the necessity for substantial energy savings across various sectors, particularly in industry. This ambitious goal requires a delicate balance between reducing energy consumption and maintaining economic strength. Concurrently, there is a noticeable shift from mass production to mass customization, driven by the need for more flexible and adaptable manufacturing processes. Cognitive robotics emerges as a pivotal technology in this context, offering enhanced capabilities for flexible production lines. One significant advantage is the ability to assemble moving parts which optimizes cycle times and therefore contributes to energy savings. This paper presents a novel approach to object tracking using NC robot-based position control, demonstrating its potential to support the industry's transition towards more sustainable and efficient manufacturing practices. The image processing algorithm, which consists of a fused methodology merging an iterative 2D image registration and stereo vision-based point cloud registration, demonstrates the ability to track an object with a mean L2-error of 3.5 mm in a dynamic environment.

关键词： Industries Point cloud compression Service robots Heuristic algorithms Energy conservation Position control Production Visual servoing Object tracking Meteorology

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Influence of the cutting edge preparation of carbide punching tools for punching of ultra-high strength steel strips

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Procedia CIRP 2024年 123卷 268-273页

作者： Nermin Redžić Sven Winter Elmar Galiev Sarah Baron Christian Stein Markus Höfer Joachim Regel Verena Kräusel Martin Dix Chemnitz University of Technology 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 Fraunhofer Institute for Surface Engineering and Thin Films IST Riedenkamp 2 38108 Braunschweig Germany

In order to ensure a robust punching process of ultra-high strength steel spring strips using carbide punching tools, a high stability of the cutting edge is required. Here the cutting edge preparation process has a significant influence. In the presented study, high-pressure abrasive water jet technology for cutting edge preparation was designed, investigated and analysed. For defining the optimal cutting edge shape regarding stresses, a numerical analysis using LS-DYNA was conducted. Within this analysis, the influence of the cutting edge rounding and symmetry was numerically tested and evaluated. Based on the results, two cutting edge shapes were selected and prepared using the high-pressure abrasive water injection jet technology. The tools were applied in the punching process up to 50,000 strokes in order to analyse the cutting performance and tool wear. With regard to a highly wear resistant tool for punching, a combination of the abrasive water injection jet preparation routine and a CVD diamond coating are under further investigation and first insights are presented additionally.

关键词： Punching Carbide Tool geometry Waterjet machining Ultra-high strength steel

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Enhancing cooling tower performance with condition monitoring and machine learning based drift detection 15

Enhancing cooling tower performance with condition monitorin...

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

作者： Nahvi, Sina Polster, Stefan Melzer, Sebastian Stoll, Anke Münnich, Marc Mannstadt, Stefan Klimant, Philipp Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Multi Kühlsysteme GmbH Zschorlauer Straße 56 Aue08280 Germany

Process cooling is crucial to many manufacturing processes. To monitor the performance of a cooling tower, it was equipped with extensive sensors for internal and environmental data acquisition. The aim is to improve reactive and predictive maintenance by estimating the actual condition as well as predicting defective behavior of the cooling tower. We designed a method, which derives the degree of defect from data of the non-defective cooling tower. A concept drift detection approach was implemented, which monitors the model estimation error of a multilayer perceptron model. Increasing model estimation error indicates changing system behavior and increasing risk of failure. © 2022 The Author(s).

关键词： Condition monitoring

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Comparative analysis of topology optimization versus material substitution: Is there a best method for vehicle weight reduction? 34

Comparative analysis of topology optimization versus materia...

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34th CIRP Design Conference, CIRP 2024

作者： Chirinda, Gibson P. Matope, Stephen Zincume, Philani Maisiri, Whisper Sterzing, Andreas University of Stellenbosch Private Bag X1 Matieland Stellenbosch7602 South Africa North West University Private Bag X6001 11 Hoffman Street Potchefstroom2531 South Africa Fraunhofer Institute of Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

The United Nations (UN) Sustainable Development Goal 13 focuses on taking urgent action to combat climate change and its impacts. Resource efficient production and strict emission regulations have made vehicle weight reduction a subject of great interest. Common lightweighting techniques include topology optimization and material substitution. The benefits include reduced raw material usage, low fuel consumption, and low carbon emissions. There is a gap in the complex balance of decision-making. If an engineer is faced with the option of topologically optimizing or materially substituting, is one method better than the other? This paper comparatively analyses these lightweight design strategies. © 2024 Elsevier B.V.. All rights reserved.

关键词： Low emission

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Test bench development and validation for blocked force measurements in six degrees of freedom 50

Test bench development and validation for blocked force meas...

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50th International Congress and Exposition of Noise Control Engineering, INTER-NOISE 2021

作者： Burkhardt, Martin Hensel, Eric Drossel, Welf-Guntram Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Str. 44 Dresden01187 Germany

ISBN: (纸本)9781732598652

For transfer path analysis (TPA) methods, the description of the source is essential. The possibilities of source characterization are as different as the TPA methods. For the classical methods, the source is considered in the assembled state with feedback from the receiver structure, while for component-based TPA the source is described without feedback from the coupled structure. In addition to TPA, source characterization is also used in the product development process for evaluation or comparisons. Also in these cases, the source must be characterized without feedback from the test structure, which can generally be realized by measuring free velocities or blocked forces. Because of the need for an external load to reach the components operating point, force measurements are often used. However, the realization of a test setup without significant influences on the measurement of forces poses some challenges. The paper presents a setup that can be used to perform a direct force measurement at one point in six degrees of freedom (dof). The necessary boundary conditions to approximate the idealized blocked force assumption are discussed, the calculation of the blocked force in six dof is presented, the structural dynamic response at a reference point is calculated and compared with operational measurements. © INTER-NOISE 2021 .All right reserved.

关键词： Force measurement

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