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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Polte, M. Polte, J. Hocke, T. Fraunhofer Institute for Production Systems Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Due to international competition, continuous increases in productivity, product quality and reduction of production costs are required. Especially, the development of milling tools made of innovative cutting materials and application-specific tool geometries for the machining of brittle materials are in focus to overcome these challenges. One approach to improve the performance and the tool behaviour concerning milling of graphite is the use of monolithic ceramic milling tools. Unfortunately, the high brittleness of the ceramic leads to breakouts on the cutting edge during the grinding process. This results in an increased maximum chipping of the cutting edge, which has a significant influence on the milling process. To improve the breakout behaviour, a cutting edge preparation with the immersed tumbling process was applied. To enable a process reliable cutting edge preparation, a suitable lapping medium, the influence of the processing time as well as the depth of immersion were investigated. Besides the maximum chipping of the cutting edge, the rounded cutting edge radius was also analysed. The results show that a process reliable cutting edge preparation of monolithic ceramic milling tools with a maximum chipping of the cutting edge RS,max ≤ 3 µm and a rounded cutting edge radius of rβ ≤ 7 µm could be realised. In future investigations, the experimental applicability of monolithic ceramic milling tools will be proved. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Brittleness

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Reduction of erosion duration for electrical discharge drilling using a nature analogue algorithm with nested strategy types 21

Reduction of erosion duration for electrical discharge drill...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Polte, M. Streckenbach, J. Osmanovic, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

The required high economic efficiency, combined with the corresponding high quality demands, in the aerospace industry as well as in mould and tool making, motivate the necessity of finding suitable parameter combinations for the process of electrical discharge machining (EDM), e.g. when introducing new materials. To counteract this, various methods are being investigated in research for the optimisation of EDM. One new method is the stochastic optimisation procedure evolution strategy (ES). Due to its metaheuristic approach, this optimisation method is excellently suited for very complex processes in which the interrelationship of the individual influencing variables is not known. This publication presents the results of the investigation of the suitability of the ES optimisation method using the example of electrical discharge drilling. For this purpose, two nested ES-types were investigated. The electrode materials used were brass for the tool and stainless steel X5CrNi18-1 for the workpiece. As a result, the erosion duration could be reduced by 30 %. This investigation forms the basis for the use of nested ES types in electrical discharge drilling. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Erosion

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Concept for Effective Identification and Initiation of Startup Investments for the Digital Transformation of Manufacturing Companies

Concept for Effective Identification and Initiation of Start...

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IEEE International Conference on Industrial Engineering and Engineering Management

作者： G. Schuh L. P. Schenk Laboratory for Machine Tools and Production Engineering (WZL) RWTH Aachen University Aachen Germany Department of Technology Management Fraunhofer Institute for Production Technology IPT Aachen Germany

The digital transformation is fundamentally disrupting established business models and existing value chains at an accelerating pace. Faced with multidimensional and inevitable changes, many incumbent companies lack necessary competences, processes, and structures to actively transform their business with sufficient speed and extent. While successful tech-companies therefore consequently rely on startup acquisitions, investments or cooperations, most incumbent manufacturing companies are not successful in systematically leveraging external corporate venturing as a catalyst for their digital transformation. Several reasons may already be found in the early phases of an investment. This applies especially to the identification of suitable startups, the determination of the potential value contribution of an investment, and the effective initiation of startup investments. Against this background, this paper presents a concept for effectively identifying and initiating external corporate venturing initiatives for the digital transformation of manufacturing companies. Thus, existing approaches in literature are discussed and analyzed to derive the requirements for developing a concept, which enables effectively identifying suitable startups for digital transformation objectives and subsequently initiating an investment. Based on these findings, the methodology and its sub-models are derived.

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Reproducibility analysis for different numerical models and experimental setups in dry orthogonal cutting of AISI 4140 steel

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Procedia CIRP 2024年 128卷 650-655页

作者： Christian Grimm Christian Menze Jannis Saelzer Florian Sauer Rocco Eisseler Hans-Christian Möhring Volker Schulze Andreas Zabel Eckart Uhlmann Institute for Machine Tools and Factory Management (IWF) Technische Universität Berlin Pascalstr. 8-9 10587 Berlin Germany Institute for Machine Tools (IfW) University of Stuttgart Holzgartenstr. 17 70174 Stuttgart Germany Institute of Machining Technology (ISF) TU Dortmund University Baroper Str. 303 44227 Dortmund Germany Institute of Production Science (wbk) Karlsruhe Institute of Technology Kaiserstr. 12 76131 Karlsruhe Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany

The design of machining processes still requires iterative parameter optimisation on the real process to achieve the demanded quality. In order to use simulation results as input for models of lubricated machining processes, which is the final aim of the presented work, it is necessary to assure that already the chip forming simulations under dry conditions produce valid results. Due to extreme conditions in the chip formation zone, including high contact stresses, temperatures and deformations, advanced requirements are imposed on a numerical model. In this work, orthogonal turning of AISI 4140 steel is simulated and experimentally investigated. Aiming for a critical examination of the conventional practice to validate simulation results only through a single experimental setup, the experiments are carried out redundantly on three varying turning lathes and measurement systems. Numerical simulations are performed using finite element analysis (FEA) within the software packages ABAQUS, AdvantEdge, DEFORM and Marc, as well as meshfree methods in the form of the finite pointset method (FPM) within MESHFREE and an element-free Galerkin method (EFG) in LS-DYNA. The obtained results demonstrate the characteristics of the individual simulation methods as well as the degree of reproducibility in experiments.

关键词： Machining Simulation Design informatics

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Particle contact conditions for cutting edge preparation of micro-milling tools by the immersed tumbling process 21

Particle contact conditions for cutting edge preparation of ...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Polte, J. Kuche, Y. Landua, F. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

For increasing tool life and cutting length of micro-milling tools the cutting edge preparation was successfully established. Using the immersed tumbling process, a reproducible cutting edge preparation with constant cutting edge radii as well as low chipping of the cutting edges can be realised. For a profound understanding of the preparation process and the process mechanisms further knowledge about the particle interactions with cutting tools as well as the particle flow mechanisms needs to be obtained. In this investigation the preparation process of micro-milling tools was analysed and the contact-mechanisms as well as the resulting pressures were investigated by simulation studies. Using the discrete element method (DEM) with the software ROCKY DEM from the company ESSS, Florianópolis, Brasil, the immersed tumbling process could be modelled and particle contacts, particle traces as well as particle interactions with the micro-milling tool can be visualized. Especially the particle-tool interactions were more accurately investigated by analysing the stresses and particles shear work as well as correlations between these parameters to prove the comparability between the process simulation and the real preparation process. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Milling (machining)

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Sensor integration in hybrid additive manufactured parts for real-time monitoring in turbine operations 21

Sensor integration in hybrid additive manufactured parts for...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Polte, J. Kersting, R. Brunner-Schwer, C. Neuwald, T. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Real-time monitoring of operation conditions such as tempeatures and vibrations enables efficiency enhancement for maintenance tasks. In energy industry monitoring of critical components such as turbine blades is essential for the operation safety. But the effective recording of critical process data is a challenging task due to the extreme operating conditions. With a hybrid processing approach combining two additive manufacturing technologies new classes of self-monitoring components become possible allowing data acquisition directly inside the component. Using the example of a turbine blade, the hybrid process chain is described. The turbine blade blank is produced via Laser Powder Bed Fusion (L-PBF) with channels for the integration of high temperature sensors. After integration cavities were closed by Laser Directed Energy Deposition (L-DED) followed by classical milling operations for part finishing. The data acquisition is integrated in state-of-the-art product lifecycle monitoring (PLM) software to create a digital twin. Evaluation shows that temperature could be successfully monitored at conditions of Θ = 550°C. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Turbomachine blades

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Simulation and compensation of the thermal behaviour of industrial robots 21

Simulation and compensation of the thermal behaviour of indu...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Polte, J. Mohnke, C. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute of Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Industrial robot systems offer a flexible, adaptable basis due to their kinematics and their mobility. An influencing variable, which is particularly relevant for processes with long process times tP, is the thermal heating and the associated thermal drift ΔAPt of the tool center point. The maximum deviation from the actual nominal position can reach up to ΔAPt = 1.5 mm. In the investigations, a simulation model for an industrial robot was created and the thermal behaviour was mapped. With this model, the thermal error ΔAPt within the working area can be determined as a function of the current position X and temperature ϑ. These data can be used for a targeted correction of the robot path. With the correction by the compensation model the amount of drift for real milling processes could be reduced to a value of ΔAPt = 0.042 mm. The results can help to reduce the influence of thermal heating and the associated thermal drift ΔAPt of the TCP without using cost-intensive measures with additional hardware and software on external computers for compensating the errors. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Error compensation

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Photocatalytic effect of TiO2-coated surfaces on the pathogenic microorganisms *** and *** 21

Photocatalytic effect of TiO2-coated surfaces on the pathoge...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Hein, C. Brehmer, A. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

The use of titanium dioxide as a strong photocatalytic substance can have a large effect in combating the spread of pathogens through heavily contaminated surfaces. For this purpose, various materials, such as metal, glass, and polymer were coated with rutile- and anatase-rich titanium dioxide by sol-gel method. The contact angle and photocatalytic activity of the coated surface were measured under UV irradiation. The anatase-rich titanium dioxide showed higher photocatalytic activity, which further increased with the coating thickness. The process temperature had an effect on the photocatalytic activity due to the temperature-dependent conversion of anatase to rutile crystal conformation. The coated surfaces had strongly reduced contact angles compared to the uncoated material. In particular, the anatase-rich surfaces resulted in superhydrophilic properties. Photocatalytically induced antibacterial activity against pathogenic microorganisms in liquid environments was demonstrated, especially for gram-negative Escherichia coli bacteria. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Titanium dioxide

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Inductive heating based on VHF-ISM radio band frequencies as technology platform for efficient heating of metallic micro-scaled bonding layers in MEMS packaging

Inductive heating based on VHF-ISM radio band frequencies as...

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Magnetic Conference - Short Papers (INTERMAG Short Papers), IEEE International

作者： Christian Hofmann Martin Kroll Sushant Panhale Maik Wiemer Andreas Kunke Karla Hiller Harald Kuhn Fraunhofer Institute for Electronic Nano Systems ENAS Chemnitz Germany Institute for Machine Tools and Production Processes University of Technology Chemnitz Germany Center for Microtechnologies University of Technology Chemnitz Germany

This paper presents a method for selective and energy-efficient induction heating of metallic microstructures to support and enhance metal bonding technologies for MEMS packaging. The technological challenges include the use of miniaturized coils for homogeneous heat distribution, the implementation of VHF-ISM radio band frequencies up to f 0 = 40.68 MHz for the generation of high frequency electromagnetic fields and the integration of the inductive equipment into a heating and bonding system. FE simulation and infrared (IR) thermography were used to characterize the inductive process with low coil currents of I 0 < 30 A and very fast heating rates of ∆T = 150 K/s. As a result, bonding times and pressures can be reduced significantly.

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Tool wear and surface roughness in micro-milling of aluminium and high-alloyed aluminium materials using cutting tools made of binderless carbide 21

Tool wear and surface roughness in micro-milling of aluminiu...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Polte, M. Hein, C. Polte, J. Wiesner, H.M. Fraunhofer Institute for Production Systems Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Micro-milling can be applied for manufacturing in a wide range of materials and complex geometries. This process is especially important for the aerospace industry. High-alloyed aluminium is a common material for aerospace applications with complex micro- and macro-geometry due to its high wear resistance. The costs-effectiveness of producing these parts can be increased by using tools with improved wear behaviour and higher life times. However, wear-resistant tools are often associated with higher tool costs, which reduces the cost-effectivness of the whole production. An innovative solution is offered by the use of a cutting tool made of binderless tungsten carbide. The micro-milling of conventional and high-alloy aluminium with a new cutting material based on a binderless tungsten carbide is analysed in this investigation. The absence of a binding phase leads to an increased hardness and improves the wear behaviour of these tools. Therefore, tools with a tool diameter of D = 10 mm were manufactured and there machinability was successfully proven. The feasibility of these innovative tools is demonstrated in a series of experiments. The experimental investigations were carried out on the five-axis high precision machine tool PFM 4024-5D PRIMACON GMBH, Peißenberg, Germany, with a workpiece made of TiAl 48-2-2. A surface roughness of Ra = 0.202 µm was detected after a path length due to primary motion lc = 70 m without any noticeable wear marks on the cutting tool. These results show the economic potential for milling tools based on binderless carbide for achieving high precision surfaces while reaching high lifetimes. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Milling (machining)

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