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WGP Congress 2014

作者： Baira, El Mustapha Kretzschmar, Michael Hollan, Robert Heitmüller, Florian Uhlmann, Eckart Institute for Machine Tools and Factory Management Technische Universität Berlin Pascalstraße 8-9 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 Berlin Germany

ISBN: (纸本)9783038352457

In this paper the technological fundamentals of dry ice blasting as a pre-treatment process for the electroplating of plastics are presented. The advantages compared to conventional pretreatment are discussed. In a series of experiments the influence of the setting parameters of the surface area roughness and surface tension of the workpiece was investigated. Furthermore, the surface parameters, which influence the adhesion strength of the electro-coating process, were identified. Finally, a model to describe the correlation between the dry ice blasting setting parameters and the surface parameters was developed. © (2014) Trans Tech Publications, Switzerland.

关键词： Electroplating

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Load-dependent Optimization of Honeycombs for Sandwich Components – New Possibilities by Using Additive Layer Manufacturing

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Physics Procedia 2014年 56卷 327-335页

作者： Fabian Riss Johannes Schilp Gunther Reinhart Fraunhofer Institute for Machine Tools and Forming Technologies (IWU) Project Group for Resource-efficient Mechatronic Processing Machines (RMV) Beim Glaspalast 5 86153 Augsburg Germany

Due to their feasible geometric complexity, additive layer manufacturing (ALM) processes show a highpotential for the production of lightweight ***, ALM processes enable the realization of bionic-designedcomponents like honeycombs, which are optimized depending upon load and outer boundary *** optimization is based on a closed-loop, three-steps methodology: At first, each honeycomb is conformed to the surface of the part. Secondly, the structure is optimizedfor lightweight *** is possible to achieve a homogeneous stress distribution in the part by varying the wall thickness, honeycombdiameter and the amount of honeycombs, depending on the subjected stresses and strains. At last, the functional components like threads or bearing carriers are integrated directly into the honeycomb *** all these steps as an iterative process, it is possible to reduce the mass of sandwich components about 50 percent compared to conventional approaches.

关键词： honeycombs sandwich components load-dependency additive manufacturing telegraphing-effect snap-in connections

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Structural Integration of PZT Fibers in Deep Drawn Sheet Metal for Material-integrated Sensing and Actuation

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Procedia technology 2014年 15卷 658-667页

作者： M. Müller B. Müller S. Hensel M. Nestler S.F. Jahn V. Wittstock A. Schubert W.-G. Drossel Professorship for Adaptronics and Lightweight Design in Production Technische Universität Chemnitz 09107 Chemnitz Germany Professorship Micromanufacturing Technology Technische Universität Chemnitz 09107 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Professorship Machine Tools and Forming Technology Technische Universität Chemnitz 09107 Chemnitz Germany

Today, adaptive sheet metal parts are manufactured by surface bonding of sensors and actuators on shaped structural parts. This paper presents a technology for direct structural integration of lead-zirconate-titanate (PZT) fibers in flat sheet metal and subsequent shaping. Microcavities are microformed into the surface of the metal sheet in which piezoceramic fibers are inserted and joined. After that, the composite is shaped by deep drawing into a complex 3D surface. The production technology is discussed in detail with regard to the limits of each process step. Functional shaped prototypes with ten interconnected parallel piezoceramic fibers were fabricated. The function as transducer and sensor for lamb waves is demonstrated and the degradation due to the shaping is compared for different parameters of the deep drawing process. The composite shapes are cups with a double curvature radius of 100 mm and 250 mm respectively. As a result, degradation of the piezoelectric function varies as a consequence of the process parameters. In the best case, a degradation of the transducer function of 33% was shown in the experiments. The cause of the decreased performance after shaping is discussed and explained by debonding mechanisms. Results of numerical simulations show good agreement with the experimental findings of the optimum process parameters.

关键词： Functional integration direct integration piezoceramic microforming microassembly deep drawing simulation function test sensor

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Spatial programming for industrial robots: Efficient, effective and user- optimised through natural communication and augmented reality

Spatial programming for industrial robots: Efficient, effect...

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WGP Congress 2014

作者： Lambrecht, Jens Krüger, Jörg Department Industrial Automation Technology Institute for Machine Tools and Factory Management Technische Universität Berlin Pascalstr. 8-9 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstr. 8-9 Berlin Germany

ISBN: (纸本)9783038352457

In this paper, we present a robot programming system taking into account natural communication and process integrated simulation as well as a unified robot control layer and an interface towards the Digital Factory for program transmission. We choose an integrative approach including markerless gesture recognition and a mobile Augmented Reality simulation on common handheld devices, e.g. smartphones or tablet-PCs. The user is enabled to draw poses and trajectories into the workspace of the robot supported with simultaneous visual feedback in Augmented Reality. In addition the user can adapt the robot program by gestural manipulation of poses and trajectories. Within a task-oriented implementation of the robot program a pick and place task was implemented through the programming by demonstration principle. With the help of a user study we evaluate programming duration, programming errors and subjective assessment compared with Teach-In and Offline Programming. The analysis of the results shows a significant reduction of programming duration as well as a reduction of programming errors compared with Teach-In. Furthermore, most participants favour the spatial programming system. © (2014) Trans Tech Publications, Switzerland.

关键词： Augmented reality

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Integration of vision/force robot control for transporting different shaped/colored objects from moving circular conveyor

Integration of vision/force robot control for transporting d...

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International Workshop on Robot Sensing (ROSE)

作者： Michael Jokesch Mohamad Bdiwi Jozef Suchý Robot Systems Chemnitz University of Technology Chemnitz Germany Tools and Forming Technology IWU Fraunhofer Institute for Machine Chemnitz Germany Technische Universitat Chemnitz Chemnitz Sachsen DE

This paper will propose algorithms for transporting different objects from moving circular conveyor with the help of vision/force robot control. Poses and speeds of the objects are calculated from sequential images captured by 3D-camera mounted on the hand of the robot. In the conveyor there are 4 slots which contain four differently formed and coloured objects. The cross sections of these objects are the square, the rectangle, the triangle and the circle. The required object will be segmented and then recognized with the help of fast image processing algorithm depending on its colour and shape. Furthermore, this paper will improve algorithm for grasping and pulling-out the required object from slot with tight clearance. For this task two different kinds of simple force control have been developed. The objects will be grasped by a 6-DoF robot with a primitive two-finger-gripper as end-effector. In the first experiment the proposed system will follow the required object until the movement of the conveyor stops. After that it will start to pull-out the object. In more complicated case, the robot will pull-out the object while the conveyor is moving. In other words, the movement of the robot will be synchronized with the movement of the object and it should grasp it at a convenient time and pose without any prior knowledge about its velocity. This paper will be supported with real experiments presenting promising results which illustrate the capability of grasping a stuck moving object with the help of vision/force robot control.

关键词： Force Grippers Trajectory Grasping Robot kinematics Cameras

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Closed loop control for shape memory alloy actuators

Closed loop control for shape memory alloy actuators

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IEEE SSD International Multi-Conference on Systems, Signals and Devices

作者： Christian Auerswald Björn Senf Jan Mehner Welf-Guntram Drossel Chair of Microsystems and Precision Engineering Technische Universität Chemnitz Chemnitz Germany Adaptronics and Acoustics Fraunhofer IWU Institute for Machine Tools and Forming Technology Chemnitz Germany

This paper describes design considerations of a control circuit for adaptive hybrid structures. These consist of a fiber-reinforced lightweight structure with a thermoplastic matrix and additional shape memory alloy wires, which can be used both as actuators and sensors. In order to use their properties, a control circuit able to heat the actuator wires and to measure their electrical resistance when used as a sensor is needed. In contrast to most references using expensive lab test equipment, a small sized, stand-alone control box is presented. It combines advantages of precision linear current sources for resistance measurement with high efficiency switch-mode converters delivering the wire heating current.

关键词： Heating Electrical resistance measurement Voltage measurement Resistance Optical fiber devices Matrix converters Magnetic properties

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Machining of Carbon Fibre Reinforced Plastics

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Procedia CIRP 2014年 24卷 19-24页

作者： E. Uhlmann F. Sammler S. Richarz F. Heitmüller M. Bilz Institute of Machine Tools and Factory Management Technische Universität Berlin Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Berlin Germany

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 adaptability of their material properties. In order to economically and reproducibly machine these materials with high part qualities, improvements in machining strategies must be made. The focus of this paper lies on innovative technologies for the machining of CFRPs whereby CVD diamond coated tools and milling tools for the improvement of milling processes have been designed. Furthermore, water jet cutting, CO2 jet cutting and grinding of CFRPs has been investigated. The quality of the machined workpieces is also an issue which requires addressing, particularly in relation to the fraying of machined edges. An innovative quantitative method for the evaluation of the workpiece quality of CFRP is presented.

关键词： reinforced plastics CVD diamond ceramic tools jet cutting abrasive machining

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Generic energy-enhancement module for consumption analysis of manufacturing processes in discrete event simulation 20

Generic energy-enhancement module for consumption analysis o...

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20th CIRP International Conference on Life Cycle Engineering, LCE 2013

作者： Stoldt, Johannes Schlegel, Andreas Franz, Enrico Langer, Tino Putz, Matthias Fraunhofer Institute Machine Tools and Forming Technology Chemnitz Germany

ISBN: (纸本)9789814451475

Customer demands for eco-friendly goods, energy supply bottlenecks or consumption/emission restrictions in many countries, as well as the current economic situation demand a conscious use of energy in industry. Manufacturers and suppliers need to increase efficiency of their products, processes and resources dramatically in order to reach agreed energy targets. To achieve substantial reductions it becomes necessary to establish predictive assessments of the energy demand for new production systems and whole manufacturing sites as standard operating procedures in systems engineering. This paper discusses a newly developed, generic energy-enhancement module, which renders resource consumption analyses within material flow simulation software possible.

关键词： Discrete event simulation

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Process Analysis of Water Abrasive Fine Jet Structuring of Ceramic Surfaces via Design of Experiment

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Procedia CIRP 2014年 14卷 442-447页

作者： M. Dittrich M. Dix M. Kuhl B. Palumbo F. Tagliaferri Technische Universität Chemnitz 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 University of Naples Federico II Department of Industrial Engineering (DII) Piazzale V. Tecchio 80 80125 Naples Italy

Machining of aluminum oxide Al2O3 can be classified as challenging by reason of its brittle and high tensile material behavior. Moreover, conventional processes for machining ceramics, e.g. using laser beam or lapping, are typically associated with lower material removal rates and high manufacturing costs. Cutting using water abrasive jet enables cutting of ceramics due to exceedingly low process forces and machining temperatures. In addition to the actual cutting process, surface structuring can be carried out using a reflecting jet by a specific adjustment of process parameters. In this context, water abrasive fine jet machining is up-and-coming due to better charge and higher precision. These factors allow the insert of the smallest geometries which either cannot be manufactured by primary shaping or are suitable for manufacturing only to a limited extent. This article describes how a process design is being executed concerning productivity and machining precision by using an analysis based on the method of the Design of Experiments (DoE). The most influencing parameters become apparent, such as water pressure, abrasive flow rate or path offset. The parameters allow a specific process dimensioning in terms of material removal rate, surface roughness and depth of penetration. Furthermore the investigations show a high reproducibility of the results using appropriate process parameters. The study illustrates that the use of the water abrasive injector fine jet permits a precise and highly efficient insertion of surface structures into ceramic materials.

关键词： water abrasive jet structuring ceramic machining design of experiments (DoE) ANOVA.

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Binderless-cBN as cutting material for ultra-precision machining of stainless steel

Binderless-cBN as cutting material for ultra-precision machi...

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WGP Congress 2014

作者： Polte, Julian Polte, Mitchel Lorenz, David Oberschmidt, Dirk Sturm, Heinz Uhlmann, Eckart Institute for Machine Tools and Factory Management Technische Universität Berlin Pascalstr. 8 – 9 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstr. 8 – 9 Berlin Germany Federal Institute for Materials Research and Testing Unter den Eichen 87 Berlin Germany

ISBN: (纸本)9783038352457

The ultra-precision cutting of steel materials is possible but needs modifications of machine tools or the workpiece material. One approach of current research is the development of cutting materials that gives the opportunity for direct cutting of surfaces with ultra-precision quality. Binderless-cBN is here one of the most promising materials. The paper shows results of experimental studies with binderless-cBN as cutting material while turning stainless steel. Various investigations were carried out to determine the wear mechanisms. Furthermore, measurements are shown regarding the surface quality. The achieved results show the high potential of binderlesscBN as cutting material for the machining of steel. © (2014) Trans Tech Publications, Switzerland.

关键词： Stainless steel

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