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12th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2012

作者： Schubert, A. Meichsner, G. Hackert-Oschätzchen, M. Zeidler, H. Fraunhofer Institute for Machine Tools and Forming Technology IWU Germany Chemnitz University of Technology Germany

ISBN: (纸本)9780956679000

Micro bores are used for several high-precision applications, especially in hydraulic systems and fuel injectors. In this case the shape, particularly the edge rounding of the injection spray hole, has a significant influence on the atomization of fluids and therefore also on the combustion process [1]. Usually these micro bores are machined by electrical discharge machining (EDM) [2]. In EDM sharp edges occur due to the process characteristics and a specific influence on the edge shape is not possible. Thus, a specific and independent adjustment of the edge rounding is required. To produce such a defined edge rounding of bores, an Electrochemical Machining (ECM) process has been investigated. The advantages of this process lie in the possible high localization of the erosion process and high achievable surface quality. The tool which is the cathode has a negative potential and determined by the design of the edge rounding [3]. An experimental set-up was developed in order to perform the investigations. This paper presents the setup and experimental investigations.

关键词： Electric discharges

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Linking process models and operating data for exploration and visualization

Linking process models and operating data for exploration an...

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Workshop on Ontology and Semantic Web for Manufacturing, OSEMA 2012

作者： Wenzel, Ken Tisztl, Marcel Fraunhofer-Institute for Machine Tools and Forming Technology IWU Department for Production Management Reichenhainer Str. 88 09126 Chemnitz Germany

Data integration between different life cycle stages of a production system is a crucial requirement for the realization of continuous computer support what is often referred to as the Digital Factory. This paper presents an approach that leverages planning data within the operation phase of a production system by applying Semantic Web technologies and linked data concepts.

关键词： Sensor networks

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Thermal Error Correction by Smart Structures

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ATZproduktion worldwide 2012年第1期5卷 26-29页

作者： Klaus Schädlich Steffen Nestmann Carsten Richter Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute for Machine Tools and Production Processes Chemnitz University of Technology Chemnitz Germany

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Thermal Interactions between the Process and Workpiece

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Procedia CIRP 2012年 4卷 63-66页

作者： Reimund Neugebauer Welf-Guntram Drossel Steffen Ihlenfeldt Carsten Richter Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Reichenhainer Straße 88 Chemnitz 09126 Germany

According to an international status report, up to 70% of the errors in cutting production can be traced back to time- and process- dependant temperature fluctuations. In particular, thermal effects from processing lead to the deformation of machine components. This affects the tool and the workpiece. This paper considers the research into interactions between process-related and thermal deformations with a focus on the high-precision machining of large workpieces. Previously conducted investigations have demon- strated the effects of the heat flow into the structures of workpieces during the machining process. As one might expect, deforma- tion occurs, which leads to deviations in shape and position. In the same way, length changes due to process-heat transfer can be observed on the tool side. This leads to displacements of the centre point of the tool, which are dependent on the tool geometry and process parameters. However, resulting production errors can often be reduced by improved process control. Considering an exam- ple from the field of mould construction, this problem has been discussed from a practical perspective. Starting with experimental analyses, the heat flow into the workpiece related to the inherent deformation was measured. This was realised using thermographic systems and displacement sensors. Relevant parameters that have a significant influence on the process were to be identified in these tests. Heat-transfer effects were analysed while varying these parameters. In the same way, this should provide support for simulative analyses and facilitate the verification of these analyses. Using computer models, it was possible to detect and evaluate thermoelastic displacements before the processing. Based on this, the findings led to appropriate countermeasures, such as the use of a modified machining sequence. The aim of all of these investigations is the development of optimal machining strategies t o help reduce manufacturing errors.

关键词： Process Thermal effects Machining

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SIMULATION AND OPTIMIZATION OF ROBOT DRIVEN PRODUCTION SYSTEMS FOR PEAK-LOAD REDUCTION 12

SIMULATION AND OPTIMIZATION OF ROBOT DRIVEN PRODUCTION SYSTE...

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Simulation Conference

作者： Soren Lorenz Matthias Hesse Anja Fischer Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Chemnitz University of Technology Chemnitz Germany

ISBN: (纸本)9781467347792

One way to improve the energy efficiency in manufacturing is the use of energy-sensitive methods in production planning. So far, the energy consumption behavior of production facilities has not been investigated in great detail. Estimates are typically obtained by connected wattage values and concurrency factors. We present a new methodology to simulate and optimize complex robot driven production systems with special emphasis on energy aspects. In particular, we show how to translate the process descriptions and energy consumption profiles into a discrete-event-based simulation model and illustrate this with an example of a car body shop facility. In order to minimize the peak-load we set up an optimization model that is based on periodic time-expanded networks. A solution of this model corresponds to a process sequence for the robots that prescribes relative starting times via additional wait intervals. This sequence is then reinserted into the simulation model to validate the improvement.

关键词： improvement sequence simulation

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Bionics Based Energy Efficient machine Tool Design

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Procedia CIRP 2012年 3卷 561-566页

作者： R. Neugebauer M. Wabner S. Ihlenfeldt U. Frieß F. Schneider F. Schubert Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute for Machine Tools and Production Technology IWP University of Chemnitz Germany Institute Lightweigt Structures SLK University of Chemnitz Germany

machine tool performance, production accuracy and energy efficiency are interdependent design criteria. To solve this design conflict, bionics – this means technical interpretation of long-term optimized biological principles – could be an effective way to accelerate innovation loops in modern machine tool development processes. In the paper, these aspects will be discussed, and selected solutions will be presented in detail.

关键词： Bionics Lightweight design Mechatronics machine tools Production technology Mobile machine

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Ultrasonic-assisted micro-EDM of deep bores: Process and discharge analysis 12

Ultrasonic-assisted micro-EDM of deep bores: Process and dis...

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12th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2012

作者： Schubert, Andreas Zeidler, Henning Wolf, Nicolas Hackert-Oschätzchen, Matthias Schneider, Jörg Chemnitz University of Technology Department of Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09107 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Department Micro- and High-Precision Manufacturing Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9780956679000

Ultrasonic vibration has been found very beneficial for the micro electro discharge machining (μEDM) of deep microstructures with high aspect ratios. In this study, the discharge properties of μEDM aided with direct ultrasonic workpiece vibration are analysed and compared to conventional μEDM machining. It can be shown that not only the number of discharges per second is significantly improved, but also the typical height of the discharge current is differently distributed. The investigation shows that the amount of open circuit states in μEDM can be noticeably reduced by using ultrasonic vibration assistance.

关键词： Ultrasonic effects

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New High-Speed machine Tool Structure by Holistic Mechatronic Systems Design

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Procedia CIRP 2012年 1卷 307-312页

作者： R. Neugebauer S. Ihlenfeldt U. Frieß M. Wabner S. Rauh Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Chemnitz University of Technology Reichenhainer Str. 70 09126 Chemnitz Germany

One possibility to increase the performance of machine tools is the achievement of higher accelerations and jerks of moved slides and stands. By this the energy consumption and machining-costs can be optimized. Nowadays machine tool structures are already optimized and further enhancements are not easily achieved. The paper deals with the mechatronic system optimization of a large-scale HSC- and HPC- portal milling centre for e.g. forming tools. This includes the identification of dynamic limiting structures and the following optimization by mechatronic system-monitoring. From process necessities a machining-time reduction by higher accelerations and improved process stability is intended. The system parameters where achieved by the implementation of a redundant axis and the usage of up-to-date lightweight design by reinforced *** over the design phase the structure was constantly monitored regarding their dynamic behaviour. Furthermore a model was used – using a state space – to prejudge the machining time for a concrete example cycle. So even before any physical prototype exists the mechatronic system-behaviour of the machine tool was pre estimated using a virtual mechatronic model. This allows for a virtual product design with a new and improved quality of safety in achieving the pre-defined goals.

关键词： HSC machining machine tool mechatronic simulation

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Light Shape Memory Actuators in Automobiles

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ATZ worldwide 2011年第4期113卷 10-15页

作者： Kunze, Holger Bucht, Andre Pagel, Kenny Zerneke, Arne Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany

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Design and Modeling of a self-sufficient Shape-Memory-Actuator

Design and Modeling of a self-sufficient Shape-Memory-Actuat...

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Conference on Active and Passive Smart Structures and Integrated Systems

作者： Bucht, Andre Junker, Tom Pagel, Kenny Drossel, Welf-Guntram Neugebauer, Reimund Fraunhofer-Institute for Machine Tools and Forming Technology IWU (Germany)

ISBN: (纸本)9780819485397

In machine tools several time and position varying heat sources causes complex temperature distributions. The resulting problems are varying thermal deformations which cause a loss of accuracy as well as non optimal drive conditions. An option to deal with that issue is to use structure integrated SM-actuators which use the thermal energy accumulated by machining processes to yield an actuator displacement. That creates a structure inherent control loop. There the shape-memory-elements work as sensing element as well as actuation element. The plant is defined by the thermal and mechanical behaviour of the surrounding structure. Because of the closed loop operation mode, the mechanical design has to deal with questions of stability and parameter adjustment in a control sense. In contrast to common control arrangements this issues can only be influenced by designing the actuator and the structure. To investigate this approach a test bench has been designed. The heat is yielded by a clutch and directed through the structure to the shape memory element. The force and displacement of the actuator are therefore driven directly by process heat. This paper presents a broad mechanical design approach of the test bench as well as the design of the SM-actuator. To investigate the thermo-mechanical behaviour of the structure-integrated actuator, a model of the test bench has been developed. The model covers the thermal behaviour of the test bench as well as the thermo-mechanical couplings of the shape memory actuator. The model has been validated by comprehensive measurements.

关键词： shape-memory-alloy actuator self sufficient structure integrated adaptive ball-screw-drive

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