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27th Metal forming Conference, MEFORM 2019

作者： Richter, Karsten Reuther, Franz Müller, Roland Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9783035714951

One effect of high influence on the dimensional accuracy during bending is springback. It inevitably occurs due to the elastic proportion in the material behavior. The impact is notably high when producing springs made of ultra-high strength spring strips of the steel grade 1.4310 (X10CrNi18-8). The high yield ratio needed to fulfil the functionalities required during application leads to dimensional inaccuracies that have to be compensated during the production process. This paper reports a simulation-based approach to predict the springback behavior of ultra-high strength spring strips with tensile strengths TS = 1500-1800 MPa. Based on the results of advanced material testing and modeling, a detailed investigation was conducted on the numerical prediction of the springback behavior of an exemplary bending process (free bending). This helps obtain deeper knowledge and understanding of the springback phenomenon and achieve suitable strategies for a more efficient industrial design for tools and processes in processing of ultra-high strength spring strips. © 2019 Trans Tech Publications Ltd, Switzerland. All rights reserved.

关键词： Finite element method

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Combined laser hardening and laser surface texturing forming tool 1.2379

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Procedia CIRP 2020年 94卷 914-918页

作者： Endalkachew Mekonnen Aragaw Eric Gärtner Andreas Schubert Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 09107 Germany Fraunhofer Inistitute for Machine tools and Forming Technology IWU Reichenhainer Str. 88 09126 Germany

This paper deals with the tribological performance of forming tool steel 1.2379. Laser hardening and Laser surface texturing are proposed as processes to improve this tribological performance. Hardening influences the surface hardness and wear resistance. While considering the parameter and the specific material, the correlation between heating power and material property is first modelled using FEM of the heat transfer. Based on the modelling result, the realization is performed by nanosecond laser and analyzed by SEM and by comparing the micro –hardness comparison with a reference value. Then textures are integrated into the hardened surface by picosecond laser ablation while focusing on its suitability for smooth dimples and on the examination by pin-on-disk tests for the effect of incorporating textures on the friction performance. Lower friction coefficients between tool and workpiece improve tool durability and product quality as well.

关键词： Laser Hardening (LH) Laser Surface Texturing (LST) Tribology forming tool 1.2379

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Interaction of Digital Twins in a Sustainable Battery Cell Production

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Procedia CIRP 2022年 107卷 1216-1220页

作者： Alexander D. Kies Jonathan Krauß Arno Schmetz Robert H. Schmitt Christian Brecher Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 Aachen 52074 Germany Fraunhofer Research Institution for Battery Cell Production FFB Mendelstr. 11 Münster 48149 Germany Laboratory for Machine Tools and Production Engineering WZL of RWTH University Campus-Boulevard 30 52074 Aachen Germany

In this paper, we propose a procedure for identifying suitable fields of action for digital twins, selecting meaningful use-cases to realize the benefits of digital twins, and prototyping their implementation in the context of battery cell production. For this purpose, we present a framework that maps out the various fields of action for realizing the benefits of digital twins in the sustainable factory of the future. In addition, the identification of suitable use-cases in the respective fields of action is described. Using the example of prototypical implementations from battery cell production, it is illustrated how different digital twins interact with each other towards the vision of sustainable production. This focuses on the digital machine, building, and product twin. The aggregation of the twins and their use enables a conservation of resources and an increase in efficiency in the production of the cells and enables the optimization of subsequent value chain steps.

关键词： Digital twin Battery Battery cell Battery cell production Sustainability

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Determination of surface shape deviation by using force-controlled burnishing

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Procedia CIRP 2020年 93卷 1275-1280页

作者： Marco Posdzich Rico Stöckmann Marco Witt Matthias Putz Chemnitz University of Technology 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

Burnishing is an effective chipless finishing process to improve the workpiece properties hardness, vibration resistance and surface quality. A force control has been established on a CNC machine tool. This force control allows the scanning of the surface during the finishing process, as part of the quality control. In this paper the realization and optimization of this technology are shown on tool steel. In addition, the measuring accuracy is examined. The aim is not only to substitute the grinding process with burnishing, but also to achieve the desired quality for the first workpiece.

关键词： measurement control micro forming

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Tool wear progression of SiAlON ceramic end mills in five-axis high-feed rough machining of an Inconel 718 BLISK 9

Tool wear progression of SiAlON ceramic end mills in five-ax...

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9th CIRP Conference on High Performance Cutting, HPC 2020

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

ISBN: (纸本)9781713835431

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. © 2020 The Authors. Published by Elsevier B.V.

关键词： Productivity

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Investigation of the influence of surface waviness of aluminium on the burnishing quality of a combined process

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Procedia Manufacturing 2020年 43卷 479-486页

作者： Marco Posdzich Rico Stöckmann Philipp Klimant Matthias Putz Chemnitz University of Technology 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

Burnishing is an effective chipless finishing process for improving workpiece properties such as: hardness, vibration resistance and surface quality. Recently, the process has been increasingly applied to prismatic workpieces and free-form geometries. Before burnishing can be carried out, a milling process created the shape of the workpiece, especially for free-form surfaces. The application of different milling tools does not only produce different roughnesses, it also creates waviness which can influence the burnishing process. This publication focuses on the relationship between roughness and waviness of the milling process on the following burnishing of ductile workpiece materials. The presented work also considers the different machining directions and tool movements of this process combination. Within the evaluation the interdependence between milling and burnishing parameters are examined and the remaining frequency components of the two processes on the generated surface are compared.

关键词： Manifacturing process Milling Finishing Surface Burnishing

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Experimental investigation on friction under machining conditions with cutting fluid supply

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Procedia CIRP 2022年 108卷 378-383页

作者： Nicklas Gerhard Tim Göttlich Daniel Schraknepper Thomas Bergs Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany Institute of Heat and Mass Transfer RWTH Aachen University Augustinerbach 6 52056 Aachen Germany Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany

In cutting processes, friction is mainly present on the rake and flank face of the tool. It has a direct influence on the thermo-mechanical loads applied in the cutting zone and thus on the surface integrity. To investigate the friction behavior experimentally, a friction test bench based on a lathe with cutting fluid supply was developed. Workpiece temperature was studied depending on machining conditions. The friction tests showed that the cutting fluid led to higher friction forces under the conditions investigated. Furthermore, the results revealed that an increase in the frictional force was accompanied by an increase in workpiece temperature.

关键词： friction test metal cutting conditions cutting fluid

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OptTopo: Automated set-point optimization for coupled systems using topology information

OptTopo: Automated set-point optimization for coupled system...

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International Conference on Control, Decision and Information Technologies (CoDIT)

作者： Gregor Thiele Theresa Johanni David Sommer Martin Eigel Jö rg Krü ger Department for Process Automation and Robotics Fraunhofer IPK Institute for Production Systems and Design Technology Berlin Germany Weierstrass Institute for Applied Analysis and Stochastics Berlin Germany Department for Industrial Automation at the Institute for Machine Tools and Factory Management Technical University of Berlin Germany

The manufacturing sector has witnessed a rapid rise in the importance of energy-efficient operation. For finding optimal set-points for industrial facilities, optimization problems of increasing complexity occur. Key challenges are the leak of derivative information and the curse of dimensionality. For systematic reduction of the search-space by decomposition of the model, a methodology for the inclusion of topology knowledge in the optimization procedure is developed. An implementation of OptTopo (Optimization based on Topology), embedded in a testbed, demonstrates its advantages compared to popular out-of-the-box-optimization. OptTopo could be integrated in energy management software offering advanced set-point control for complex facilities.

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Fully coupled wet cylindrical turning simulation using the Finite-Pointset-Method

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Procedia CIRP 2021年 102卷 43-48页

作者： Eckart Uhlmann Enrico Barth Alexander Quellhorst Tobias Seifarth Jörg Kuhnert Kaissar Nabbout Martin Sommerfeld Technische Universität Berlin Institute for Machine Tools and Factory Management (IWF) Chair of Machine Tools and Manufacturing Technology Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Industrial Mathematics ITWM Fraunhofer-Platz 1 67663 Kaiserslautern Germany Otto von Guericke University Magdeburg Institute of Process Engineering Universitaetsplatz 2 39106 Magdeburg Germany

In industrial machining operations, many turning processes are carried out under wet conditions. In contrast, most simulation tools are only suitable for dry cutting processes due to challenges of modeling fluid-structure-interactions (FSI). In this paper, a wet, fully coupled cutting simulation using the Finite-Pointset-Method (FPM) is presented and validated for industrially relevant cylindrical turning. To facilitate the required reduction of the calculation effort, different routines like adaptive numerical discretization are applied. The results indicate different cutting fluid effects like evaporation areas around the chip.

关键词： Turning Cutting fluid Simulation

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Improvements to a method for determining leg length following total hip arthroplasty

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Journal of Medical Engineering and technology 2020年第2期44卷 69-75页

作者： Wendler, Toni Heilemann, Martin Grunert, Ronny Möbius, Robert Schmidt, Michael Schleifenbaum, Stefan Prietzel, Torsten Centre for Research on Muscoskeletal Systems Leipzig University Leipzig Germany Faculty of Medicine Institute of Anatomy Leipzig University Leipzig Germany Department of Orthopaedic Trauma and Plastic Surgery Leipzig University Leipzig Germany Fraunhofer Institute for Machine Tools and Forming Technology Dresden Germany Department of Neurosurgery Leipzig University Leipzig Germany Department of Orthopaedic Trauma and Plastic Surgery Zeisigwaldkliniken Bethanien Chemnitz Chemnitz Germany

Discrepancy in leg length does frequently occur as a side effect of total hip arthroplasty and may lead to reduced patient satisfaction as well as injury in the sequalae. It is consequently important to reduce leg length discrepancy where-ever technically possible. This may be achieved by recording precise intraoperative measurements and using different sized implanted components. The aim of the given study was to improve the accuracy of a previously validated optic measurement system (OMS) to reduce leg length discrepancy. This pre-existing OMS was first trialled and based on these preliminary findings developed further. Using this improved system, measurements were taken in models and cadavers. Inter observer reliability of the improved OMS was assessed. The system is introduced in the given technical feasibility study. Its accuracy was greater in the model setup (swivel joint: 772.7 ± 1.5 mm;ball joint: 770.0 ± 3.7 mm;reference: 772 mm) compared to the trial using cadaveric tissues (588.8 ± 5.7 mm;reference: 586 mm). Results of two examiners were similar. The third one measured significantly shorter values (p=.011). The results of the measurements with the OMS indicate that a significant increase in accuracy (p = 2.076×10−6) has been achieved compared to the previously reported system, however, a further improvement to measurement accuracy is necessary for this to be applied clinically. © 2020, © 2020 Informa UK Limited, trading as Taylor & Francis Group.

关键词： Arthroplasty

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