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Investigation of the Machinability of CoCr Alloys in Orthogonal Cutting

Procedia CIRP 2023年 118卷 584-589页

作者： Christoph Zachert Markus Meurer Daniel Schraknepper Thomas Bergs Laboratory for Machine Tools and Production Engineering (WZL) of RWTH University Campus-Boulevard 30 52074 Aachen Germany Fraunhofer Institute for Production Technology (IPT) Steinbachstraße 17 52074 Aachen Germany

The increasing demand for medical prostheses, such as a dental prosthesis, leads to an increasing need for machining of CoCr alloys. The material properties of CoCr, such as high tensile strength, toughness, and wear resistance, are advantages for long-term use, but mean great challenges for machining. In this paper, the machinability of CoCr alloy varying cutting speed, rake angle and depth of cutting was investigated. Surface quality, cutting forces and chip shape were considered. The knowledge gained from the basic investigations can be used to increase tool life and improve productivity.

关键词： CoCr Alloys Machining Broaching

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Building Blocks for an Automated Quality Assurance Concept in High Throughput Battery Cell Manufacturing

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Procedia CIRP 2023年 120卷 904-909页

作者： Johann-Philip Abramowski Alexander D. Kies Enno Hachgenei Alexander Kreppein Dennis Grunert Robert H. Schmitt Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 Aachen 52074 Germany Laboratory for Machine Tools and Production Engineering WZL of RWTH University Campus-Boulevard 30 52074 Aachen Germany

The increasing demand for sustainable energy raises the request for battery cells. Industry and research are faced with challenges like complex processes, complex machinery, and many intra-process interactions within the field of battery cell production. Major problems, such as low process stability and quality fluctuations, lead to high scrap rates. Result is a reduced sustainability in the production process. To address these challenges, the main content of this paper is a conceptual design of a virtual Quality Gate (QG) system, for quality assurance and quality prediction. The concept of virtual QG combines physical and digital elements. On the physical side actuators, sensors, and measurement technologies are included to provide the raw data. The digital side of virtual QG includes necessary elements for data acquisition, data processing, data analysis and information provision for the decision-making process in the real world. Focus of the presented approach is illustrating how to select the appropriate location of QG for quality decisions in conjunction with the derivation of necessary decisions, process information and evaluation of measurement technology that is needed.

关键词： Automated Quality Assurance Databased Decision Making Sustainability Quality Gates

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Reactive online scheduling of mobile resources for adaptive layout evolution in line-less assembly system

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Procedia CIRP 2022年 107卷 270-275页

作者： Lea Kaven Jonas Rachner Thomas Schmid Amon Göppert Robert H. Schmitt Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Aachen Germany Fraunhofer Institute for Production Technology IPT Aachen Germany

Assembly systems are required to be more flexible due to unpredictable resource and demand fluctuations. Line-less assembly systems (LAS) implement flexible job routes through multi-purpose resources and flexible transportation systems. Moreover, a completely reactive layout through (re-)arrangement of stations with mobile resources enables reconfigurations without interrupting production. A scheduling that can handle the complexity of dynamic events is necessary to plan job routes and control transportation in such an assembly system. Since the system layout and the job scheduling influence each other, only an integrated view of layout planning and scheduling implements a reactive system behaviour. Existing pre-planning methods with fixed cycle times are not designed for reactive layout optimization during line-less assembly operations with mobile resources. Therefore, the contribution of this paper is an integrated online optimization architecture for layout evolution using mobile resources and simultaneous job scheduling to increase the efficiency of LAS. The optimization is implemented using modular matching and scheduling algorithms considering temporary station setup states and parallel processing based on zone restrictions. The proposed algorithms are connected to a modular discrete-event simulation and scenario analysis tool of LAS. The simulation and control architecture is validated by applying an industry-based use case. The reactive layout evolution, including station exchanges and mobile resource repositioning are benchmarked with nonflexible control methods. Results show that the developed control system allows for shorter average lead-time and increased throughput and utilization of (mobile) resources.

关键词： Online Scheduling Reactive Layout evolution Layout Planning Flexible Manufacturing

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A Novel Approach for Modelling Loads on Profiled Cutting tools

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Procedia CIRP 2025年 133卷 394-399页

作者： Jan Wolf Rocco Eisseler Nithin Kumar Bandaru Martin Dienwiebel Hans-Christian Möhring Institute for Machine Tools University of Stuttgart Holzgartenstraße 17 70174 Stuttgart Germany Institute for Applied Materials (IAM) Microtribology Center µTC Karlsruhe Institute of Technology Straße am Forum 5 76131 Karlsruhe Germany Fraunhofer Institute for Mechanics of Materials (IWM) Wöhlerstraße 11 79108 Freiburg Germany

Wear of cutting tools is known to affect the surface integrity of the workpiece and significantly contributes to machine downtime. Modelling the cutting process by means of Finite Element Analysis (FEA) yields advantages to gain insights in the loads applied on the cutting tool. For the process of profile grooving only 3D modeling approaches can be employed to capture the non-linear loads relevant for wear modelling. Caused by a transient cutting phase with changing cutting conditions, capturing the wear relevant state variables over the grooving process requires huge computational resources. Aiming to reduce the simulation time for profile grooving, a novel approach is presented which transferes the cutting process to an orthogonal cutting test bench with a significantly reduced workpiece length. Workpieces are prepared with a groove that matches the shape of the tool before preparing them with a ramp or a step to enable studying the grooving process for continuously changing cutting widths and a step for abruptly changing cutting widths to resemble the freedom of design of grooving tools. The proposed approach is validated by evaluating the mechanical loads of grooving operations conducted on a turning center, on the orthogonal cutting test bench and the corresponding 3D cutting simulations with two different tool shapes to study the approach with continuously and abruptly changing cutting widths. Results show a high similarity of the cutting experiments with the proposed modeling approach with a median absolute error of 7.3% on selected points of the grooving process while offering a reduced cutting distance of 99% over the turning operation. The results show, that the required computational resources for modeling profile grooving processes can significantly be reduced while keeping the loads on the tool within reasonable accuracy. The findings promise a more efficient approach for modelling loads on profiled cutting tools with possible applications in wear model

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Development of a mechanical, biocide-free method of disinfection for cathodic dip coating processes 21

Development of a mechanical, biocide-free method of disinfec...

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

作者： Uhlmann, E. Hilt, M. Hein, C. Cudazzo, M. Huth-Herms, K. Jahnke, C. Quast, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Fraunhofer Institute for Manufacturing Engineering and Automation IPA Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Technical fluids are often contaminated by bacteria as Burkholderia cepacia (B. cepacia), which is found in different industrial issues and affects manufacturing process chains by the formation of planktonic cell-aggregates and biofilms within the working fluids. B. cepacia is one of nine species of the Burkholderia cepacia complex (Bcc), a group of gram-negative, motile, non-spore-forming, and rod-shaped bacteria. Because of the opportunistic pathogenicity to plants, animals, humans, and the multi-drug and biocide resistance, B. cepacia is difficult to treat. This study aims to provide an application to reduce the germ numbers ng in an eco-friendly and continuous process without the use of biocides. The approach to disinfect technical fluids is to apply high shear forces in a rotor-stator assembly to the fluid. A prototype of the rotor-stator assembly with a variably adjustable shear gap gs and rotor speed srot was constructed. First experiments with a frequency frot 10 Hz ≤ frot ≤ 40 Hz a shear gap gs = 83 µm and gs = 166 µm showed a reduction of germ number ngr = 99.6 %. It concluded that the disinfection of technical fluids by a rotor-stator assembly is a biocide-free alternative. In addition to defined process parameters such as shear gap gS, temperature ϑ, frequency frot and time of machining process tmp, also the peripheral speed vp, rotational speed vrot, flow rate fr and shear stresses τ were used to assess the machining result and to develop an overall concept for disinfection of technical fluids. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Stators

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Characterization of vibration in continuous generating grinding and resulting influence on tooth flank topography and gear excitation

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Procedia CIRP 2021年 99卷 208-213页

作者： Jonas Böttger Simon Kimme Welf-Guntram Drossel Institute for Machine Tools and Production Processes IWP Chemnitz University of Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

Besides harmonic meshing frequencies, excitation behavior of gears is highly affected by micro geometry of tooth surface caused by waviness on gear flank topography. Errors in finishing processes like continuous generating gear grinding are examined to demonstrate their impact on gear flank topography under consideration of characteristic waviness with a simulation model. Results of an experimental investigation on manufactured topography and measured transmission error show well correlation with the model. The pursued analysis of characteristic cutting volume in frequency domain of systematically considered process errors is a reasonable step towards the prediction of process conditions in the manufacturing process.

关键词： Grinding Gear Vibration Simulation

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Green incremental learning - Energy efficient ramp-up for AI-enhanced part recognition in reverse logistics

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Procedia CIRP 2023年 116卷 414-419页

作者： Marian Schlüter Robert Schimanek Paul Koch Clemens Briese Vivek Chavan Pinar Bilge Franz Dietrich Jörg Krüger Fraunhofer Institute for Production and Design Technology (IPK) Pascalstr. 8-9 Berlin 10587 Germany Technical University Berlin Institute for Machine Tools and Factory Management Pascalstraße 8-9 10587 Berlin Germany

Artificial Intelligence (AI) has made significant progress in supporting circular economy and reverse logistics by learning from diverse data to predict, e.g., routes or to assist workers in sorting. However, it remains an open question how AI can be integrated and trained into such operational processes, where little to no data has been collected previously. Traditionally, AI models would only be rated by their accuracy. This paper aims to introduce the concept of green incremental learning, i.e. rating AI models not only for their accuracy but to evaluate energy efficiency as well. A ramp-up of a data-driven AI system for part recognition is explored under consideration of energy efficiency. Therefore, we combine online and incremental learning, working with growing data sets to simulate a ramp-up phase. We present experiments of incremental learning on business and image data, partially supported by regular joint training steps. We start local CPU-based machine learning and prediction on business data from the first sample. Finally, we compare incremental learning to traditional batch learning and show energy-saving potential of up to 62 % without a significant drop in accuracy.

关键词： Circular economy reverse logistics incremental learning computer vision machine learning

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Concept of a plug-and-play, machine Learning Digital Twin of the production resource for Detailed Capacity Planning and Scheduling

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Procedia Computer Science 2025年 253卷 1266-1275页

作者： Mario Luber Sarah Wagner Marc Wegmann Johannes Schilp Fraunhofer Institute for Casting Composite and Processing Technology IGCV Am Technologiezentrum 10 86159 Augsburg Germany Technical University of Munich Institute for Machine Tools and Industrial Management Boltzmannstraße 15 85748 Garching Germany University of Augsburg Institute of Computer Science Am Technologiezentrum 8 86159 Augsburg Germany

Due to the progress of Digital Production and the Industrial Internet of Things, continuous shop floor data is available with high coverage, accuracy, and in high detail for Production Planning and Control software. Detailed Capacity Planning and Scheduling (DCPS) can benefit by applying the Digital Twin concept and machine Learning for an accurate and automated virtual representation of the production resource. However, the effort and difficulty required for data connection, data preparation, and modelling are high. Connection standards enable interoperability and plug-and-play software, and constitute an opportunity to reduce the effort and difficulty. This article compiles requirements regarding the virtual representation of the production resource for DCPS. It then proposes the concept of a plug-and-play, machine Learning Digital Twin to meet these requirements. The elements of the according Digital Twin software are described, and the need for future research is identified.

关键词： Production Planning Control Digital Twin machine Learning interoperability

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Subjective validation for short-term material flow simulation

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Procedia CIRP 2025年 134卷 562-566页

作者： Heiner Reinhardt Boran Bogdanow Roman Arnold Bastian Prell Philipp Klimant Frank Seifert Mahtab Mahdaviasl Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Volkswagen Sachsen GmbH Kauffahrtei 47 09120 Chemnitz Germany Technical University of Applied Sciences Wildau Hochschulring 1 15745 Wildau Germany Professorship Virtual Technologies Hochschule Mittweida - University of Applied Sciences Technikumplatz 17 09648 Mittweida Germany Chemnitz University of Technology Straße der Nationen 62 09111 Chemnitz Germany Institute of Machine Tools and Control Engineering Technische Universität Dresden Helmholtzstraße 7a 01062 Dresden Germany

Material flow simulation, by means of discrete event simulation (DES), is frequently applied to support decision-making in production planning and control. However, manual modeling can be time-consuming and error-prone. Hence, numerous studies propose the automation of model generation and synchronization to overcome these challenges. However, in this context, validation techniques are rarely addressed. Therefore, we introduce a subjective validation technique for short-term material flow simulation based on a coherent methodology for data acquisition and visualization. The methodology is utilized to evaluate the outcome of an approach for computerized model generation and simulation. By means of an industrial use case, we hypothesize the causes for the deviation between the operation of a manufacturing system and the simulation of its generated virtual companion.

关键词： Digital Twin Simulation Quality Optimization Manufacturing system Control Analysis

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Virtual Two-Dimensional Electrode Representation Through the Spatial Transformation of Production Data

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Procedia CIRP 2024年 130卷 413-418页

作者： Johannes Lindenblatt Zewen Chen Christian Mose Alessandro Sommer Rüdiger Daub Technical University of Munich TUM School of Engineering and Design Institute for Machine Tools and Industrial Management (iwb) Garching Germany Siemens AG Digital Industry Factory Automation Battery Solutions Munich Germany Fraunhofer Institute for Casting Composite and Processing Technology (IGCV) Augsburg Germany

The production of battery cells is characterized by a multi-process production chain in which the individual processes significantly impact intermediate and product properties. A virtual representation of the produced electrode enables the analysis of cause-and-effect relationships and can be used for quality assurance. While the virtual representation of components or products is already common in other engineering domains, an approach to a holistic virtual representation of the electrode in battery cell production does not yet exist. A high level of data accuracy in multiple dimensions is required to reduce scrap within electrode production and automate processes. Therefore, this work presents a comprehensive data acquisition, preprocessing, and analysis methodology to get a multi-dimensional representation of the electrode properties and process parameters. Multiple data modeling options were analyzed to generate a uniform and complete database of all sensor data. Gaussian process regression and Kriging modeling were used to interpolate the mass loading of electrodes after the coating process so that the holistic virtual representation of the electrode was enabled. The use of industrial edge computing and interpolation of sensor data enables a more accurate, virtual representation of produced electrodes.

关键词： Battery Production Virtualization Industry 4.0 Production Automation Digital Twin

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