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53rd CIRP Conference on Manufacturing Systems, CMS 2020

作者： Hänel, Albrecht Schnellhardt, Thorben Wenkler, Eric Nestler, Andreas Brosius, Alexander Corinth, Christian Fay, Alexander Ihlenfeldt, Steffen Institute of Manufacturing Technology Technische Universität Dresden Dresden01062 Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden01062 Germany Institute of Automation Technology Helmut Schmidt University Hamburg22043 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden01187 Germany

This paper describes a method for creating a digital twin based on planning and process data for machining processes by using the example of components in the aerospace industry. This development is based on an information model that combines the properties and relationships of relevant information and data involved in the manufacturing process. This system integrates mathematical (technical-technological) models and algorithms for the determination of process parameters as well as planning-relevant information from the machining process. The technology of the digital twin makes it possible to recognize problems directly in the machining process, e.g. deviations from the planning specifications and to derive targeted measures for quality assurance and optimization of the machining process. © 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://***/licenses/by-nc-nd/4.0/) Peer-review under responsibility of the scientific committee of the 53rd CIRP Conference on Manufacturing Systems

关键词： Machining centers

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Comparison of Resistive and Optical Strain Measurement for Early Fracture Detection

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Current Directions in Biomedical Engineering 2020年第3期6卷

作者： Carabello, Alina Neupetsch, Constanze Werner, Michael Rotsch, Christian Drossel, Welf-Guntram Zajonz, Dirk Chemnitz University of Technology Adaptronics and Lightweight Design in Production Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Iwu Chemnitz/ Dresden Germany Zeisigwaldkliniken Bethanien Chemnitz Germany

To increase learning success in surgical training, physical simulators are supplemented by measurement technology to generate and record objective feedback and error detection. An opportunity to detect fractures following hip stem implantation early can be measurement of occurring strains on bone surface. These strains can be determined while using strain gauges, digital image correlation (DIC) or photoelasticity. In this research strain gauges and DIC were compared regarding their suitability as strain measurement tools for use in physical simulators. Therefore a testing method was described to replicate the implantation of a hip stem. Testing devices modelled on a realistic prosthesis were pressed into prepared porcine femora in a two-step procedure with a material testing machine. The local strains occurring on bone surface were determined using an optical measurement system for DIC and strain gauges. The initial fractures in the tested femora are located medial-anterior in most cases (73,6%). With increasing indentation depth of the test device, the strains on bone surface increase. Comparing the local strains determined by DIC and strain gauges consistencies in curves are noticeable. Maximal determined strains before fracturing amount to 0,69% with strain gauges and 0,75% with DIC. In the range of the fracture gap, strain gradients are determined by using DIC. However the detected surfaces are of low quality caused by gaps and motion artefacts. The results show strains on bone surfaces for early fracture detection are measurable with strain gauges and DIC. DIC is assessed as less suitable compared to strain gauges. Furthermore strain gauges have greater level of integration and economic efficiency, so they are preferred the use in surgical training simulators. © 2020 by Walter de Gruyter Berlin/Boston 2020.

关键词： Image correlation

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Retrieving properties of manufacturing systems from traceability data for performance evaluation and material flow simulation

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Procedia CIRP 2021年 104卷 20-25页

作者： Heiner Reinhardt Marc Münnich Bastian Prell Roman Arnold Fabian Krippner Marek Weber Frank Seifert Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Technical University of Applied Science Wildau Hochschulring 1 15745 Wildau Germany Volkswagen Sachsen GmbH Motorenwerk Chemnitz Kauffahrtei 47 09120 Chemnitz Germany Chemnitz University of Technology Straße der Nationen 62 09111 Chemnitz Germany

The operation of manufacturing systems is increasingly accompanied by data-driven continuous improvement processes and product traceability is required. Commonly, radio-frequency identification (RFID) technology is applied to track the flow of a uniquely-identifiable workpiece along various stations or waypoints within a factory. Based on an automotive use case, this paper describes how to analyze the resulting traceability data in order to identify several properties of a manufacturing system. The acquired knowledge can support performance evaluation and facilitate model building for material flow simulation as a foundation for digital twins and cyber-physical production systems.

关键词： Knowledge management Algorithm Analysis Condition monitoring Manufacturing system Complexity Man-machine system Pattern recognition

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Development and Validation of Bone Models using Structural Dynamic Measurement Methods

Development and Validation of Bone Models using Structural D...

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作者： Neupetsch, Constanze Hensel, Eric Werner, Michael Meißner, Sven Troge, Jan Drossel, Welf-Guntram Rotsch, Christian Chemnitz University of Technology Professorship for Adaptronics and Lightweight Design in Production Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz/Dresden Germany

Vibration measurement and signal analysis methods are common to evaluate the functionality and characteristics of technical components in different industrial and scientific areas. Modal analysis for example is a standard method to characterize the dynamic behavior of a structure and enables the development of validated bone models. The state of the art of analyzing bone structures does not include the modal damping, although it has a significant influence on the dynamic characteristics. Within the presented investigations, the modal analyses have been performed contactless with respect to excitation and response acquisition, which implies that there are no influences of shakers or sensor couplings. Therefore, an automatic impulse hammer and a 3D Scanning Laser Doppler Vibrometer were used for excitation and response detection. Various supports of the test specimens, surface pretreatments, excitation points and excitation impulses were examined to optimize the measurement setup and process. Experimental modal analysis data were analyzed by curve fitting methods to determine the modal parameters. To evaluate different structures and effects of damping, 3D printed artificial bones and animal in vitro bones were used to perform the measurements. To produce the cortical layer of the artificial bone models, volume models were generated based on medical image data and printed by polyamide-based selective laser sintering. The cancellous bone was represented by different foam fillings for the artificial bones. Thereby, the variation of the porosity was achieved by using different mixing ratios of polyurethane foam and hardener. Furthermore, the modal damping parameters were determined from the measurement of animal bones. The measurement time was optimized during the practical implementation of the parameter determination to minimize the influence of drying and decomposition processes on the measurement results. © 2019 by Walter de Gruyter Berlin/Boston.

关键词： Structural dynamics

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Linked Data Architecture for Assistance and Traceability in Smart Manufacturing

Linked Data Architecture for Assistance and Traceability in ...

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9th EASN International Conference on Innovation in Aviation and Space, EASN 2019

作者： Friedemann, Marko Wenzel, Ken Singer, Adrian 1Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Traceability systems and digital assistance solutions are becoming increasingly vital parts of modern manufacturing environments. They help tracking quality-related information throughout the production process and support workers and maintenance personnel to cope with the increasing complexity of manufacturing technologies. In order to support these use cases, the integration of information from different data sources is required to create the necessary insights into processes, equipment and production quality. Common challenges for such integration scenarios are the various data formats, encodings and software interfaces that are involved in the acquisition, transmission, management and retrieval of relevant product and process data. This paper proposes a Linked Data based system architecture for modular and decoupled assistance software. Its web-oriented approach allows to connect two usually disparate data sets: semantic descriptions of complex production systems on the one hand and high-volume and high-velocity production data on the other hand. The proposed concept is illustrated with a typical example from the manufacturing domain. The described End-of-Line quality assessment on forming machines is used for traceability and product monitoring. © The Authors, published by EDP Sciences, 2019.

关键词： Linked data

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Influence of a Hydrostatic Pressure Shift on the Flow Stress in Sheet Metal

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Procedia Manufacturing 2020年 47卷 1245-1249页

作者： Sam Coppieters Mathias Jackel Christian Kraus Toshihiko Kuwabara Frederic Barlat KU Leuven Technology Campus Ghent Ghent Belgium Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Tokyo University of Agriculture and Technology Tokyo Japan GIFT-POSTECH Pohang Republic of Korea

The stack compression test (SCT) and the strain-rate controlled hydraulic bulge test (HBT) enable to determine the large strain flow curve of sheet metal under an identical deformation mode and balanced biaxial tension. This equivalence should lead to identical flow behavior if plastic yielding is independent of the hydrostatic stress. However, a discrepancy is observed in the flow curves of DP600 steel sheet determined by the SCT and the HBT. In order to avoid uncertainty with respect to dissimilar test conditions, the average strain-rate in both material tests is carefully controlled. Additionally, evidence is provided that friction can be sufficiently minimized yielding a homogeneous SCT up to a true plastic strain of 0.3. Assuming reliable experimental data, the hypothesis that the hydrostatic pressure shift between the stress states in the SCT and the HBT causes the observed difference in flow behavior is scrutinized. Theoretical considerations regarding the effect of a superimposed hydrostatic pressure (i.e. putting a material under a pressure environment for a certain stress state) on the flow stress, as suggested by Spitzig et al. [1] and Spitzig and Richmond [2], are used to understand the effect of a pressure shift between two stress states on the flow stress. Finally, the theoretical considerations are experimentally validated using the discrepancy in flow behavior of DP600 measured by the SCT and the HBT.

关键词： sheet metal stack compression test hydraulic bulge test pressure dependency

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Manufacturing of glass fibre/PBT-spincom yarns for innovative composite processing 18

Manufacturing of glass fibre/PBT-spincom yarns for innovativ...

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18th European Conference on Composite Materials, ECCM 2018

作者： Scheffler, Christina Hiller, Janett Krüger, Matthias Haase, Rico Weise, Dieter Garray, Didier Spickenheuer, Axel Leibniz-Institut für Polymerforschung Dresden e.V. Dept. Composite Materials Hohe Straße 6 Dresden01069 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dept. Business Unit Car Bodies and Cell Structures Chemnitz Germany SIRRIS Seraing Liège/Wallonia Belgium

ISBN: (纸本)9781510896932

The aim of this work was the development of GF (glass fibre)/ PBT (polybutylene therephthalate) SpinCOM yarns that are commingled online during the spinning process using sizing formulations that enable textile processability as well as high fibre-matrix interaction. Epoxy- and polyurethane-based sizings have been applied and were evaluated by micromechanical (single fibre pull-out test) and macromechanical (transverse tensile test of unidirectional plates) testing. Finally, a material combination was selected to be processed by Tailored Fiber Placement (TFP) to textile preforms with a variable-axial, load adapted fiber design. These preforms were consolidated in a low energy and resource consuming process using novel light and low cost forming tools produced by incremental sheet metal forming (ISF) technology. Finally, a low cost solution for thermal processing even for complex shaped TPC parts is demonstrated by the geometry of a bicycle saddle. © CCM 2020 - 18th European Conference on Composite Materials. All rights reserved.

关键词： Polybutenes

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Digital service application for the recalibration of a machine tool through Augmented Reality-supported data acquisition

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IOP Conference Series: Materials Science and Engineering 2022年第1期1235卷

作者： F Arnold G Lemme M Hess S Witt S Ihlenfeldt Institute of Mechatronic Engineering Chair of Machine Tools Development and Adaptive Controls TU Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Dresden Germany Software AG Darmstadt Germany METROM Mechatronische Maschinen GmbH Hartmannsdorf Germany

The effort for checking and correcting the spatial movement accuracy of a processing machine with 5 axes is very high. Calibration and recalibration must be carried out directly on the machine by the machine supplier or a company specializing in this. This is associated with high personnel and long machine downtimes. These constraints can be improved by using modern methods. A consistent approach of an AR-supported measurement procedure for the preparation and execution of a required measurement run and the execution of the calibration itself as a digital service is presented. This enables rapid execution by the machine operator himself using a DoubleBallBar measurement system without the need of the presence of the machine manufacturer. The determination of the calibration parameters on the basis of the measurement data is then carried out by the machine manufacturer and provided as a service. The basis for such a secure and auditable service is a digital service platform. This serves as an intermediary between the user and the machine manufacturer and uses distributed ledger technology. The approach presented is the subject of current development work.

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Haptic feedback is more important than VR experience for the user experience assessment of in-car human machine interfaces 31st

Haptic feedback is more important than VR experience for the...

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31st CIRP Design Conference 2021, CIRP Design 2021

作者： Schölkopf, Lasse Lorenz, Mario Stamer, Mareike Albrecht, Lina Klimant, Philipp Hammer, Niels Tümler, Johannes Volkswagen AG Berliner Ring 2 Wolfsburg38436 Germany Professorship for Production Systems and Processes Chemnitz University of Technology Reichenhainer Straße 70 Chemnitz09126 Germany Department of Orthopedics Trauma and Plastic Surgery University Hospital Leipzig Liebigstraße 20 Leipzig04103 Germany Department of Macroscopic and Clinical Anatomy Medical University of Graz Harrachgasse 21 Graz8010 Austria Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany Professur Ingenieurinformatik Anhalt University of Applied Sciences Bernburger Str. 55 Köthen06366 Germany

The user experience (UX) of a product is important for a customer's decision, especially in the automotive sector. In recent years, a frontloading of UX assessments from physical prototypes to virtual prototypes has occurred. Nevertheless, there are clear indications that established UX assessments methods cannot simply be transferred 1-to-1 from real to virtual evaluation setups as results get biased. For the UX assessment of an in-car human machine interface (HMI) the haptic properties of the knobs and buttons are just as important as their visual features. Therefore, it is mandatory to also simulate the haptic behavior of the in-car HMI in virtual reality (VR) assessment scenarios. However, accurately simulating this haptic behavior adds considerable costs and effort, diminishing the beneficial effects of VR UX assessments. Due to confidentiality reasons the volunteering participants of VR UX studies in the automotive sectors are typically employees with a varying degrees of VR experience. It is unknown if this gap in VR experience biases the results of UX assessments in VR. This paper presents a UX assessment study of an in-car HMI in VR in comparison to reality. From a practitioners viewpoint two research question are investigated: (1) How much is the UX assessment impaired by missing haptic simulation? (2) Does VR experience influence UX assessment ratings in VR? The results show that missing haptic feedback severely diminishes UX ratings, leaving no doubt that meaningful UX assessments in VR can only be performed when haptic is included. This means that more effort has to be put into earlier VR assessments severely reducing its benefits compared to UX assessments with physical prototypes. However, the VR experience of the participants only has a slight effect on the UX assessment results. © 2021 Elsevier B.V.. All rights reserved.

关键词： Virtual reality

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Increasing flexibility of self-pierce riveting using numerical and statistical methods

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Procedia Manufacturing 2019年 29卷 264-270页

作者： Tobias Falk Mathias Jäckel Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 01187 Dresden Germany

Self-pierce riveting with semi-tubular rivets (SPR-ST) is currently the most important joining technology for modern mixed-material car body constructions. In these body designs a multitude of material and thickness combinations occurs and for many of these combinations individual parameters of the SPR-ST process like the rivet length and die geometry have to be determined. This paper shows an approach to increase the flexibility of the SPR-ST process by the determination of the process parameters using FEM simulations in combination with statistical methods. In the described investigations one parameter set is derived for the SPR-ST process from seven different material combinations with steel and aluminum materials. For each material combination a simulation model is validated by the comparison of the joint geometry and force-stroke diagram from the experimental reference joints with the results from the process simulation. On the basis of the validated simulation models, numerical sensitivity analyses are carried out for each material combination to investigate the correlations between the process parameters die geometry and rivet length with important quality characteristics of the joint like interlock, minimal thickness of the die-sided sheet and joining force. With the knowledge of these studies computed process optimizations are carried out, in order to define one die geometry to join all seven material combinations in good quality, so a tool changing is no longer required. The reduction from seven to only one optimized SPR-ST tool saves costs as well as processing time and production space.

关键词： Self-pierce riveting Sensitivity analyses Tool optimization

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