As reported before, the Lightweight design department of the fraunhoferinstitute IWU is collaborating with several foundries in manifold projects. The objectives show a large variety starting with energy management a...
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As reported before, the Lightweight design department of the fraunhoferinstitute IWU is collaborating with several foundries in manifold projects. The objectives show a large variety starting with energy management activities and leading to product and technology development. Especially in high pressure die casting, most of the products are material minimized till the edge of the castability. The wall thickness is decreased to their very limits, holes are integrated for lightweight reasons and structures modified by topology optimization pushing this traditional industrial sector to the newest state of technology. Many attempts have been published trying to combine that high level serial production technology with the cellular structures for lightweight reasons on the one hand and for material efficiency on the other. Anyway, till now none of them is dealing with real serial die casting parts. The geometry of the parts needs to be adapted to the requirements of the pore generation procedure. As these approaches are rather complex, in some cases the invested energy, time and additives consume the savings reached by the pore integration. The intention of the project is based upon the omnipresent resource efficiency. By intensive technological investigation of the state of the art and several practical test runs, almost all published strategies of pore generation in high pressure die casting have been analyzed. The industrial partner of the project rejected all of the current approaches as irrelevant for serial application forcing us to create new ideas. Differing from common metal foam structures the objected material savings are around 20-25%. By changing the die-casting-machine setup and several parameters the first parts in original geometry have been realized reaching the target of material reduction. Mostly homogenous pores have been integrated in common serial parts containing a wall thickness of below 3 mm while the outer shell is still completely closed and
The increased energy demand in emerging markets, dwindling oil reserves and the planned nuclear phase-out in various industry nations cause energy prices to increase significantly. In order to sustain their competitiv...
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The increased energy demand in emerging markets, dwindling oil reserves and the planned nuclear phase-out in various industry nations cause energy prices to increase significantly. In order to sustain their competitiveness, companies need to mind their energy consumption. Through levelling and temporal shifting of power demands, the operative control of factories allows for an energy cost minimised production. Hence, energy efficiency becomes an organisational aim in all management levels of an enterprise which needs to be included as an optimisation objective in MES. This paper discusses model-based manufacturing control strategies, which provide energy-saving resource scheduling and order dispatch in automotive plants.
A new generation of binderless-cBN for micro machining of ferrous materials has been investigated. In this paper, detailed information about cBN-tools for turning operations, cutting edge preparation by grinding and p...
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ISBN:
(纸本)9780956679031
A new generation of binderless-cBN for micro machining of ferrous materials has been investigated. In this paper, detailed information about cBN-tools for turning operations, cutting edge preparation by grinding and polishing as well as the first results of cutting tests are given.
Aluminum foams already are in automotive and machine tool industry serial application. Only little interest has been shown by the construction or building industry so far. The still relatively high material costs, lac...
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Aluminum foams already are in automotive and machine tool industry serial application. Only little interest has been shown by the construction or building industry so far. The still relatively high material costs, lack of connecting and joining techniques, as well as reservations of the users towards new material solutions are the reasons why. In the building industry design for efficiency is taking into account the principles of lightweight material and structure. Especially sandwich panels with aluminum foam core are of high interest. The high rigidity with low weight and high resistance to fire are the major advantages of these panels. Also these semi-finished materials shield electromagnetic waves and show extensive vibration reduction and sound insulation. Combining the sandwiches with additional functions such as cooling and heating by integrated tubes is one example.
The measuring time tm is a limiting factor for the application of industrial X-ray 3D Computed Tomography (CT) as a test method for measuring tasks, especially in technical application areas with varying components [1...
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ISBN:
(纸本)9780956679031
The measuring time tm is a limiting factor for the application of industrial X-ray 3D Computed Tomography (CT) as a test method for measuring tasks, especially in technical application areas with varying components [1]. The paper shows the influence of the number of projections np and the rotation technique on the image quality in dependence of the geometry and material of test objects for industrial X-ray 3D CT.
For a flexible and resource efficient generation of moulds for micro-injection moulding, additive manufacturing processes such as Selective Laser Melting are used. Electrochemical machining (ECM) is a promising techni...
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ISBN:
(纸本)9780956679031
For a flexible and resource efficient generation of moulds for micro-injection moulding, additive manufacturing processes such as Selective Laser Melting are used. Electrochemical machining (ECM) is a promising technique for the final shaping of the mould and for creation of the injection cavity with required precision, since ECM is independent of material hardness and ductility [1]. The latter property is important concerning SLM produced moulds, which are often harder and stronger than cast moulds [2]. In this study, electrochemical machining of two SLM materials, AlSi10Mg Aluminium alloy and 18Ni-300 Nickel-based maraging tool steel, is analysed. A unique process applying a continuous electrolytic free jet (Jet-ECM) is used that offers the possibility to generate micro-structures by controlling the nozzle movement and the current flow [3].
The implementation of carbon fiber reinforced plastics (CFRPs) in the aeronautical industry has increased dramatically in recent years due to their favourable combination of low weight and high strength as well as the...
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Showing process-relevant information of assembly lines is an important task in production, e.g. for diagnostic purposes. Accessing the relevant manufacturing values during production requires extensive knowledge of th...
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Showing process-relevant information of assembly lines is an important task in production, e.g. for diagnostic purposes. Accessing the relevant manufacturing values during production requires extensive knowledge of the used machines and their control systems (e.g. PLC, CNC) and could cause a delay of the production process. Therefore, this paper presents an Augmented Reality (AR) based application for mobile devices realizing a user-friendly and problem-oriented visualization of relevant information directly on-site. The AR application uses a uniform graphical user interface. Due to this the user does not need to handle different human machine interfaces.
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