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Intelligent Pattern Recognition of a SLM machine Process and Sensor Data

Procedia CIRP 2017年 62卷 464-469页

作者： Eckart Uhlmann Rodrigo Pastl Pontes Abdelhakim Laghmouchi André Bergmann Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstraße 8-9 Berlin 10587 Germany Technische Universität Berlin - Institute for Machine Tools and Factory Management (IWF) Pascalstraße 8-9 Berlin 10587 Germany

Selective Laser Melting is an additive manufacturing process, in which the research has been increasing over the past few years to meet customer-specific requirements. Therefore, new manufacturing parameters have been monitored raising the number of sensors in the machines. Consequently, it leads to a bigger amount of data and difficulties to perform manual data analysis. In order to improve the analysis, this paper illustrates a possibility of pattern recognition using a different historical process and sensors data from a SLM machine. The results are evaluated using an intelligent tool for algorithms configuration and data analysis developed at fraunhofer IPK.

关键词： Pattern recognition data analysis SLM additive manufacturing sensor data

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Intrinsic manufacture and design of positive locking fibre reinforced thermoplastic metal hollow structures 17

Intrinsic manufacture and design of positive locking fibre r...

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17th European Conference on Composite Materials, ECCM 2016

作者： Barfuss, D. Grützner, R. Garthaus, C. Gude, M. Institute of Lightweight Engineering and Polymer Technology Technische Universität Dresden Holbeinstr. 3 Dresden01307 Germany Fraunhofer-Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 Chemnitz09126 Germany

ISBN: (纸本)9783000533877

In contrast to common and classical joining technologies for composite metal hybrid structures such as bonding and riveting, profile and contour joints offer promising potential for novel lightweight structures. First and foremost, joining systems with a form closure function enable to pass very high loads into rod- and tube-shaped fibre reinforced structures, whereby a high degree of material utilization for composite parts can be achieved. This paper presents an intrinsic manufacturing approach for the efficient production of carbon fibre reinforced thermoplastic hollow composite structures with multi scale structured metallic load introduction elements. © 2016, European Conference on Composite Materials, ECCM. All rights reserved.

关键词： Manufacture

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Flexible IT-platform to Synchronize Energy Demands with Volatile Markets

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Procedia CIRP 2017年 63卷 318-323页

作者： Dennis Bauer Eberhard Abele Raphael Ahrens Thomas Bauernhansl Gilbert Fridgen Matthias Jarke Fabian Keller Robert Keller Jaroslav Pullmann René Reiners Gunther Reinhart Daniel Schel Michael Schöpf Philipp Schraml Peter Simon Fraunhofer Institute for Manufacturing Engineering and Automation IPA Nobelstrasse 12 70569 Stuttgart Germany Institute of Production Management Technology and Machine Tools Technische Universität Darmstadt Otto-Berndt-Straße 2 64287 Darmstadt Germany Fraunhofer Institute for Applied Information Technology FIT Schloss Birlinghoven 53754 Sankt Augustin Germany Fraunhofer Research Institution for Casting Composite and Processing Technology IGCV Beim Glaspalast 5 86153 Augsburg Germany

Based on the goal of exiting nuclear and fossil energies within the electricity generation, the percentage of renewable energies in the energy mix rises. Due to renewable energies’ dependence on natural resources like sun or wind this development leads to a volatile energy supply on the markets. To satisfy their customers’ needs even with a volatile energy supply, especially companies of the manufacturing sector need to consider this development. Production processes need to be developed further to be more energy efficient and to be adaptable in their energy demand to volatile supply. This includes being operable on various power levels or with different kinds of energy such as electricity or gas. Energy-flexible production processes need to be supported by flexible IT solutions. While there are already solutions for demand-side-management on the company side as well as on the market side, there are no holistic solutions yet, allowing for integration regardless of company or market boundaries. Therefore, this paper presents the concept of a service-oriented architecture for a flexible IT-platform to synchronize energy demands with volatile markets. A holistic approach allows for integration of companies as well as energy markets and enables an automated and efficient exploitation of demand response potentials.

关键词： Digital Manufacturing System Energy efficiency Flexibility

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Task-based Motion Control of Digital Humans for Industrial Applications

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Procedia CIRP 2017年 62卷 535-540页

作者： Luigi Pelliccia Franziska Klimant Agostino De Santis Giuseppe Di Gironimo Antonio Lanzotti Andrea Tarallo Matthias Putz Philipp Klimant Institute for Machine Tools and Production Processes Technische Universität Chemnitz Reichenhainer Str. 70 09126 Chemnitz Germany PRISMA Lab DIETI Università degli studi di Napoli Federico II Via Claudio 21 80125 Napoli Italy Joint Lab IDEAS DII Università degli studi di Napoli Federico II P.le Tecchio 80 80125 Napoli Italy Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Reichenhainer Str. 88 09126 Chemnitz Germany

Nowadays digital substitutes of human beings (digital humans), capable of interacting with digital mock-ups in Virtual Reality, are widely used in many fields of engineering (e.g. ergonomics, product design, maintenance, and training). Nevertheless, the animation process of digital humans is still a time-consuming task, and its accuracy and reliability strongly depend on the experience and the skills of the operator. This paper presents an innovative algorithm capable of significantly speeding up the animation process of digital humans, allowing the operator to focus only on the so-called “task-related control points”. This approach allows also to easily conduct biomechanical analyses. The algorithm has been tested with reference to several application scenarios in Virtual Reality.

关键词： Virtual reality Algorithm Kinematics Digital humans

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Manufacturing of Long Products Made of Innovative Lightweight Materials

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Acta Metallurgica Sinica(English Letters) 2015年第12期28卷 1496-1502页

作者： Karsten Richter Roland Müller Andreas Kunke Verena Kr? usel Dirk Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Professorship Forming and Joining (UFF) Technische Universit?t Chemnitz

The processing of innovative lightweight materials to sheet metal components and assemblies with globally or locally defined properties is the object of this work. It takes a load-dependent design of components and assemblies, for example, based on the composition of different construction materials or a targeted setting of component areas with specified characteristics to fully exploit the lightweight potential when substituting conventionally used materials. Different process chains for the manufacturing of roll-formed long products made of magnesium alloys and high-strength steels with locally defined properties will be presented in this paper. Depending on the kind of material to be formed and the desired product characteristics, different temperature managements are needed for capable processes. Due to limited formability at room temperature, magnesium alloys require a heating of the forming zones above 200–225 °C throughout the bending process in order to activate additional gliding planes and to avoid any failures in the radii. The realization of local hardening effects requires at least one process-integrated heat treatment when roll forming manganese–boron steels. For both processes, it is imperative to realize a heating and cooling down or quenching appropriate for the manufacturing of long products with the required quality. Additionally, proper line speeds that allow a continuously operated economical production have to be considered. Research results including design, FEA, realization and experimentation of the mentioned process chains and strategies will be described in detail.

关键词： Roll forming Heat treatment Lightweight component Light metals Manganese steels AZ31 magnesium alloy

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Modeling Approach for Situational Event-handling within Production Planning and Control Based on Complex Event Processing

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Procedia CIRP 2017年 63卷 271-276页

作者： Julia Pielmeier Stefan Braunreuther Gunther Reinhart Fraunhofer Research Institution for Casting Composite and Processing Technology (IGCV) Provinostr. 52 86153 Augsburg Germany Institute for Machine Tools and Industrial Management (iwb) Technical University Munich Boltzmannstr. 15 85748 Garching Germany

Nowadays industrial production environments are complex, volatile, and driven by uncertainties. Manufacturing companies are striving for flexibility and adaptability to cope with these challenges and remain competitive. Market requirements such as shortened product life cycles, increasing number of variants, and customized products lead to complexity in manufacturing systems. Possible approaches to cope with such challenges can be found in the field of ‘Industrie 4.0’. In particular, decision-making and real-time reaction systems are one way to handle the complexity. To cope with this complexity, digitalization like the vision of ‘Industrie 4.0’ can offer different solutions. However, digitalization leads to an increase of the amount of data describing the status of products and resources within an industrial production environment. In order to achieve a near real time monitoring and control of production and logistics processes, intelligent processing and analyzing of the acquired data is necessary. As a result of this development, so called “complex event processing” (CEP) is essential for analyzing extensive data streams in real-time. In order to derive the rules for a CEP engine, an event model has to be described to visualize the relations, constraints and abstraction levels of production processes. The main focus within this paper is a modeling approach for the situational handling of events within production planning and control. The requirements of the modeling method are focused on the use case of a mass production for carbon-fiber-reinforced plastic CFRP components.

关键词： Modeling Production Process control

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Energy-efficiency in a Hybrid Process of Sheet Metal forming and Polymer Injection Moulding

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Procedia CIRP 2016年 40卷 109-114页

作者： D. Landgrebe V. Kräusel A. Rautenstrauch A. Albert R. Wertheim Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany Institute for Machine Tools and Forming Technology Technische Universität Chemnitz Reichenhainer Straße 70 09126 Chemnitz Germany

Hybrid processes are an efficient solution for shortening process chains and improving performance. As an example a process combination of sheet metal forming and polymer injection molding is introduced and investigated. The merging of forming and moulding processes into a single step process allows generating potential cost-savings, especially for medium to large production volumes. Based on the technological comparison between the conventional and the new process chain, the determination of the energy consumption and the detected impacts concerning the process efficiency are presented, showing that approx. 20% less energy is required due to using only one tempered tooling and reduction of handling operation.

关键词： forming Energy Efficiency Polymer Moulding Hybrid process

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Influence of Microstructures on Tribological Systems - Development of Process and Surface Structure

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Procedia CIRP 2016年 46卷 281-284页

作者： Gerhard Regel Matthias Putz Peter Blau Carsten Hochmuth Uwe Frieß Maik Fiedler Fraunhofer Institute for Machine Tools and Forming Technologie IWU 09126 Chemnitz Germany

Requirements are constantly rising for friction and wear reduction of moved components in combustion engines. Numerical simulations and investigations have demonstrated the potential of microstructured surfaces at tribological highly stressed sliding contacts, in particular the cam- tappet contact area. Using the innovative cutting process of single-grain scratching, the microstructures shall be implemented. The requirements of this implementation are defined based on simulations for cam-tappet contacts. After determining boundary conditions an empirical process model for the scratching process is created. It forms the basis for fundamental investigations carried out on the technology development. By conducting subsequent experimental investigations, relationships between the influencing parameters are established. Finally the process model and the results of the experiments lead to a device for integrating this process into existing production chains.

关键词： Friction Tribology Wear Process development Abrasive grain Microstructure

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Adaptronic Applications in Cutting machines

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Procedia CIRP 2016年 46卷 303-306页

作者： W.-G. Drossel A. Bucht K. Pagel T. Mäder T. Junker Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

Adaptronic systems are able to improve high performance cutting technologies making them more stable, economic and efficient leading to a higher product quality. The main objectives of adaptronic systems in production technologies, beyond controlling process parameters, are either reducing vibration or generating them. The latter topic is a highly innovative area of research since it offers alternative approaches to improve product quality and optimize machining processes regarding efficiency and economy. Current research at fraunhofer institute for machine tools and forming technology IWU focuses on facilitating the transfer of scientific knowledge to industrial solutions. Therefore, possible reasons preventing industrial application of adaptronic systems in cutting machines are identified and initial ideas to overcome these problems are presented.

关键词： machine tool Adaptive control Vibration assisted machining

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Process simulation and experimental validation of Hot Metal Gas forming with new press hardening steels

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Journal of Physics: Conference Series 2017年第1期896卷

作者： A. Paul F. Reuther S. Neumann A. Albert D. Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology (Fraunhofer IWU) Reichenhainer Straße 88 09126 Chemnitz Germany

One field in the work of the fraunhofer institute for machine tools and forming technology IWU in Chemnitz is industry applied research in Hot Metal Gas forming, combined with press hardening in one process step. In this paper the results of investigations on new press hardening steels from SSAB AB (Docol®1800 Bor and Docol®2000 Bor) are presented. Hot tensile tests recorded by the project partner (University of West Bohemia, Faculty of Mechanical Engineering) were used to create a material model for thermo-mechanical forming simulations. For this purpose the provided raw data were converted into flow curve approximations of the real stress-real strain-curves for both materials and afterwards integrated in a LS-DYNA simulation model of Hot Metal Gas forming with all relevant boundary conditions and sub-stages. Preliminary experimental tests were carried out using a tool at room temperature to permit evaluation of the forming behaviour of Docol 1800 Bor and Docol 2000 Bor tubes as well as validation of the simulation model. Using this demonstrator geometry (outer diameter 57 mm, tube length 300 mm, wall thickness 1.5 mm), the intention was to perform a series of tests with different furnace temperatures (from 870 °C to 1035 °C), maximum internal pressures (up to 67 MPa) and pressure build-up rates (up to 40 MPa/s) to evaluate the formability of Docol 1800 Bor and Docol 2000 Bor. Selected demonstrator parts produced in that way were subsequently analysed by wall thickness and hardness measurements. The tests were carried out using the completely modernized Dunkes/AP&T HS3-1500 hydroforming press at the fraunhofer IWU. In summary, creating a consistent simulation model with all relevant sub-stages was successfully established in LS-DYNA. The computation results show a high correlation with the experimental data regarding the thinning behaviour. The Hot Metal Gas forming of the demonstrator geometry was successfully established as well. Different hardness values could b

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