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Life Cycle Gates: Extending the concept of Virtual Quality Gates along circular product life cycles

Procedia CIRP 2023年 120卷 493-498页

作者： A.-S. Wilde K. Tonn T. Abraham Christoph Herrmann Institute of Machine Tools and Production Technology Chair of Sustainable Manufacturing and Life Cycle Engineering Technische Universität Braunschweig Langer Kamp 19b 38106 Braunschweig Germany Volkswagen AG 38436 Wolfsburg Germany Fraunhofer Institute of Surface Engineering and Thin Films Bienroder Weg 54E 38108 Braunschweig Germany

Reaching a higher level of sustainability of a products life cycle became a strategic goal for many companies over the past years. To achieve that higher level of sustainability, the transformation of linear product life cycles (cradle to grave) into circular life cycles (cradle to cradle) in the context of a Circular Economy (CE) is one promising approach. However, implementing a circular life cycle results in higher requirements in defining the best fitted strategy at the end of each product use stage depending on economic, environmental and social factors. In order to cope these increased requirements, the whole product life cycle has to become more transparent. This transparency can be reached by a holistic digital representation and virtual quality control of all life cycle stages. To implement a virtual quality control in each stage and enable the monitoring and controlling of the whole life cycle, the concept of Virtual Quality Gates can be extended. Virtual Quality Gates divide a defined manufacturing chain into different virtual, quality-relevant decision points to check the product quality and ensure a defined quality state before further manufacturing steps are approved. This concept can be transferred to each life cycle stage to ensure a holistic optimization of the products life cycle quality and an optimized selection of a strategy at the end of each use stage. This paper presents a framework for the implementation of virtual quality gates into product life cycles. These extended quality gates are defined as Life Cycle Gates, which are virtual decision points to optimize a product life cycle. The demand and applicability of the concept is shown for a mechanical recycling process of automotive parts.

关键词： Life Cycle Gates Life Cycle Technologies Circular Economy Virtual Quality Gates

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Influence of the weld pool geometry on solidification cracking in partial penetration high power laser beam welding

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Procedia CIRP 2022年 111卷 397-400页

作者： Nasim Bakir Ömer Üstündag Andrey Gumenyuk Michael Rethmeier Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 10587 Berlin Germany Institute of Machine Tools and Factory Management Technische Universität Berlin Pascalstraße 8-9 10587 Berlin Germany

Solidification cracking is still a serious problem in laser beam welding, especially in the welding of thick-walled plates. The influence of weld pool geometry on solidification cracking in partial penetration welding of thick plates is investigated within scope of this study. Therefore, a specific experimental setup of steel and quartz glass in butt configuration and on the side with high-speed camera were used to record the weld pool shape. In addition, the influence of laser inclination angle on the weld pool geometry and on solidification crack formation was investigated. The results show a bulge in the weld pool root, which is separated from an upper region by a necking region. This leads to a case where there are three different longitudinal region lengths with different solidification zones. This temporal sequence of solidification strongly promotes the formation of solidification cracks in the weld root.

关键词： Laser beam welding (LBW) solidification cracking partial penetration weld pool shape

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Temporal analysis of event-discrete alarm data for improved manufacturing

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Procedia CIRP 2020年 93卷 742-746页

作者： Heiner Reinhardt Jan-Peter Bergmann Anke Stoll Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

Efficient response to machine failures is crucial for improving machine availability. In practice, the number of alarms occurring during the operation of manufacturing systems could overwhelm even experienced machine operators. Manufacturing execution systems (MES) therefore often allow for alarm data acquisition as well as its filtering and aggregation to reduce the occurring information overload. However, manual configuration of these systems may be cumbersome and time-consuming. Hence, we propose an event-discrete method for temporal alarm data analysis to support the configuration process.

关键词： Man-machine system Maintenance Pattern recognition Knowledge management Algorithm Analysis Automation Condition monitoring Manufacturing system Complexity

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A novel approach for increasing the traceability of 3D printed medical products

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Current Directions in Biomedical Engineering 2020年第3期6卷

作者： Matvieieva, Nataliia Neupetsch, Constanze Oettel, Markus Makdani, Varun Drossel, Welf- Guntram Fraunhofer Institute for Machine Tools and Forming Technology Iwu Nöthnitzer Straße 44 Dresden Germany

According to the European Medical Device Directive (MDR (EU) 2017/745), medical products of all risk classes are obliged to be labelled with Unique Device Identification Codes (UDI). In order to meet the requirements of the MDR, a novel method of identification for additively manufactured metallic products was developed at the fraunhofer institute for machine tools and forming technology (IWU). The method provides a product traceability within its production process and during the whole product lifespan, and also functions as a counterfeit protection. This paper shows the integration of a unique identification during an additive manufacturing process for a titanium part. The readout of the integrated identification was executed using ultrasonic and eddy current methods, as well as micro computed tomography. Obtained results are discussed in the paper. © 2020 by Walter de Gruyter Berlin/Boston 2020.

关键词： Laser beams

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Application of tool electrodes oxidised with humid and dry air during the electro-discharge drilling of MAR-M247 alloy 21

Application of tool electrodes oxidised with humid and dry a...

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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. Camin, B. Chocholaty, O. Dinh, N.C. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany Institute for Materials Science and Technology Metallic Materials Technische Universität Berlin Germany Faculty of Mechanical Engineering Department of Material Science and Technology University of West Bohemia Czech Republic

ISBN: (纸本)9780995775190

The requirements and challenges of machining advanced materials in the field of aerospace, automotive and tool industry are increasing constantly. Due to their mechanical properties, cutting of high-strength materials such as superalloys is severely limited. Electro-discharge drilling can be used for the manufacturing of holes in hard to machine materials. Although electrical discharge machining (EDM) is successfully applied to the machining of holes in turbine blades, a lack of performance and challenges concerning the geometrical accuracy still remain. By applying inner flushing, the resulting electrically conductive debris is flushed through the lateral working gap, increasing the probability of arcs and short circuits. The resulting increased tool wear, conicity of the hole, limited hole depth and process instabilities are still challenging in electro-discharge drilling. In order to decrease the effects of the arcs and short circuits, a surface modification is applied to increase the electrical resistance of the lateral surface of the tool electrode. As a result, the mentioned impairments occur less frequently due to decreased occurrence of arcs and short circuits in the lateral working gap. For the present investigation copper tool electrodes were thermally oxidised in dry and humid air with different durations and used afterwards for electro-discharge drilling of MAR-M247. The tests were carried out on the machine tool AGIETRON Compact 1 from the company GF AgieCharmilles, Losone, Switzerland. Holes with a depth of t = 11 mm were drilled using various surface-modified tool electrodes with a diameter of d = 2 mm. Oxidation with dry air and a extended oxidation time resulted in a 18 % lower erosion duration, accompanied by an increase of the linear wear of the tool electrode Δle below 10 %. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Oxidation

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Tool wear progression of SiAlON ceramic end mills in five-axis high-feed rough machining of an Inconel 718 BLISK

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Procedia CIRP 2021年 101卷 13-16页

作者： Richard Zimmermann David Welling Tommy Venek Philipp Ganser Thomas Bergs Makino Europe GmbH Fraunhofer-Institute for Production Technology IPT Aachen Laboratory for Machine Tools and Production Engineering of RWTH Aachen University

The machining of heat-resistant super alloys such as Inconel 718 is still challenging. Processes are characterized by low productivity and high tool costs compared to the machining of steel or titanium materials. SiAlON ceramics offer potential for productivity increases, but are rarely used in industrial application due to uncertainties regarding the correct machining parameters or applicable tool life criteria. In this study, a complex miniaturized high-pressure compressor blisk component was machined using ceramic end mills for the roughing operation. Based on these experiments, the productivity increase of SiAlON ceramic roughing tools was compared to conventional cemented carbide tools. Additionally, a detailed tool wear analysis was conducted. Thereby, a wear-related tool radius decrease could be observed over the machined volume and a linear approximation could be made. Multiple tools exhibited similar tool wear progression.

关键词： Nickel alloy Machining Cutting tool Ceramic End milling Productivity Wear

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Introducing readiness scales for effective reuse of open source hardware

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Procedia CIRP 2022年 109卷 635-640页

作者： Robert Mies Martin Häuer Mehera Hassan Technische Universität Berlin Institute for Machine Tools and Factory Management PTZ 3 Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Digital engineering Pascalstr. 8-9 10587 Berlin Germany

Open source hardware (OSH) describes physical products that allow for "anyone to study, modify, produce, and distribute them". While OSH principles aim to support design reuse, recent studies have challenged whether this is properly applied in practice. Therefore, this article delivers an assessment scheme that allows to identify the readiness of OSH designs for reuse. Testing the scheme on OSH ventilator designs collected by the Publnv ventilator project showed overall good usefulness of the scheme and emphasised the need of unambiguous assessment scales based on common standards. Less than two thirds of Publnv’s listed projects fulfilled minimum criteria for openness.

关键词： open innovation open source hardware open source product development technology readiness documentation readiness design reuse

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Development and Validation of Bone Models using Structural Dynamic Measurement Methods

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Current Directions in Biomedical Engineering 2019年第1期5卷 343-345页

作者： Neupetsch, Constanze Hensel, Eric Werner, Michael Meißner, Sven Troge, Jan Drossel, Welf-Guntram Rotsch, Christian Chemnitz University of Technology Professorship for Adaptronics and Lightweight Design in Production Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz/Dresden Germany

Vibration measurement and signal analysis methods are common to evaluate the functionality and characteristics of technical components in different industrial and scientific areas. Modal analysis for example is a standard method to characterize the dynamic behavior of a structure and enables the development of validated bone models. The state of the art of analyzing bone structures does not include the modal damping, although it has a significant influence on the dynamic characteristics. Within the presented investigations, the modal analyses have been performed contactless with respect to excitation and response acquisition, which implies that there are no influences of shakers or sensor couplings. Therefore, an automatic impulse hammer and a 3D Scanning Laser Doppler Vibrometer were used for excitation and response detection. Various supports of the test specimens, surface pretreatments, excitation points and excitation impulses were examined to optimize the measurement setup and process. Experimental modal analysis data were analyzed by curve fitting methods to determine the modal parameters. To evaluate different structures and effects of damping, 3D printed artificial bones and animal in vitro bones were used to perform the measurements. To produce the cortical layer of the artificial bone models, volume models were generated based on medical image data and printed by polyamide-based selective laser sintering. The cancellous bone was represented by different foam fillings for the artificial bones. Thereby, the variation of the porosity was achieved by using different mixing ratios of polyurethane foam and hardener. Furthermore, the modal damping parameters were determined from the measurement of animal bones. The measurement time was optimized during the practical implementation of the parameter determination to minimize the influence of drying and decomposition processes on the measurement results. © 2019 by Walter de Gruyter Berlin/Boston.

关键词： Structural dynamics

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Condition monitoring of multi-material lightweight components through a sensitive outer skin using Fiber-Bragg-Grating sensors

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Procedia CIRP 2022年 110卷 311-316页

作者： M. Warnck M. Binder G. Edelmann M. Früchtl I. Taha 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 Boltzmannstr. 15 85748 Garching Germany Hochschule Aalen Polymer Technology Beethovenstraẞe 1 73430 Aalen Germany

Multi-material structures for lightweight applications are continuously gaining increased importance, especially in future industries, such as wind power or electro mobility. Material combinations of metal and fiber reinforced polymer (FRP) composites subjected to high or cyclic loads are critical at the interface. The integration of sensors in multi-material components allows for additional functionalities from needs-based maintenance to continuous condition monitoring and fault detection. In addition, the obtained data even further allows the exploitation of the full potential for lightweight design. Inspired by nature and following the concept of Biological Transformation, the technical approach for the implementation of condition monitoring on multi-material components makes use of the periosteum in the endoskeleton of vertebrates as a bionic model. This concept was adopted for metal-FRP multi-material combinations with the integration of Fiber-Bragg-Grating (FBG) sensors within the FRP. By subjecting components to vibration by external excitation, damages in form of delamination were successfully detected by analyzing the state-dependent natural frequencies of the component. Test specimens were prepared and the influence of various parameters such as frequency, location and direction of the excitation as well as the fixture of the samples during excitation on the natural frequency was investigated. The approach was further demonstrated on the example of a component from the sports industry. The chosen snowboard is expected to fulfill lightweight requirements on the one hand while being exposed to irregular high loads.

关键词： Multi-material lightweight design Sensor integration Fibre-Bragg-Grating Sensors Condition Monitoring Biological Transformation Fibre-Reinforced Plastics PBF-LB/M

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Method for quantifying the value of information for production control in cross-company value-adding networks

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Procedia Manufacturing 2021年 54卷 1-6页

作者： Alexander Zipfel Daniel Herdeg Philipp Theumer Fraunhofer IGCV Fraunhofer Institute for Casting Composite and Processing Technology IGCV Augsburg Germany Technical University of Munich Institute for Machine Tools and Industrial Management (iwb) Garching b. München Germany

The advancing digitalisation of production processes increases data availability and enables real-time information sharing between value-adding partners. However, despite the technological feasibility, information relevant for production control to initiate target-oriented countermeasures against disturbances are rarely shared with value-adding partners. To create incentives for companies to exchange information for short-term production control, the respective values of information must be determined. This publication presents a method for quantifying the value of information for production control in cross-company value-adding networks on a monetary basis. The input for the required performance measurement system is derived from a simulation model of the production system. Applying the approach to a simulative scenario validates the method’s functionality and the potential of information sharing to reduce disturbance cost.

关键词： Value of information Production control Value-adding network

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